234 Mazda BT 50 Factory Service Repair Manual J97M PDF

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

provide information covering normal
service repairs and maintenance for the
wanger.
As all information in this manual was the

best available at the time of printing,
vehicle specification and other information
will be updated in Service Information.
Ford Motor Company
APPLICATION:
This manual is applicable to vehicles
beginning with the Vehicle Identification
Numbers (VIN), and related materials shown
on the following page.
L
GENERAL INFORMATION 00SECTION
._-------------------------------
GENERAL INFORMATION ... 00-00
00-00 GENERAL INFORMATION

VEHICLE IDENTIFICATION NUMBER HOW TO USE THIS MANUAL ........ . 00-00-2
(VIN) CODE . ..................... 00-00-1 ABBREVIATION . .................. . 00-00-4
VEHICLE IDENTIFICATION NUMBERS
(VIN) . ........................... 00-00-1
VEHICLE IDENTIFICATION NUMBER (VIN) CODE

DCFOOOOOOOOOB05
MNBBS1 01 06W123456
==I==I=I=l ~I____ Serial No.
1 - ._ _ _ _ _ _ _ _ _ _ -..:...P..:.:la:..:.;..nt W=A. A. Thailand
6= 2006
Production year 7= 2007
No meaning 0
1=WL-C (2.5 L-DI)

2= WL-3 (2.5 L Diesel-Emission Turbo)
L--_ _ _ _ _ _ _ _ _ _ _...:E:;,;n:o!:gii:.:..:.ne~tyJ:.PEe:_ 9= WE-C (3.0 L-DI)
D= 2268-2721 kg {5001--6000 Ibs}

L--_ _ _ _ _ _ _ _ _--..::G::..ro:.::s:.:.s...:.ve:::.:h.:::ic::.:le:...w:.:.:e::::ig~h:.:..t E= 2722-3175 kg {6001-7000 Ibs}
A= Regular cab.-without box
B= Regular cab.-with box
E= Double cab.-without box
F= Double cab.-with box
1= Stretch cab.
(with Rear Access System) -without box
2= Stretch cab.
L--_ _ _ _ _ _ _ _ _ _ _ _ _ ~~~~
Bodv stvle (with Rear Access System) -with box
L--_ _ _ _ _ _ _ _ _ _ _ _ _ _ Product ~~~~

sorce S= Japan (for Thailand)
B= Seatbelt only
D= with Air bag (Driver side) .~
L= with Air bag (Driver and Passenger)
L--_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _..:..A.::.:.ir..,::b=a U= with Air bag (Driver, Passenger and Side air bag)
World manufacturer identification MNB= FORD (Thailand)

DCFOOOZWB001
l 00-00-1
-
GENERAL INFORMATION
HOW TO USE THIS MANUAL DCFOOOOOOOOOB03

This manual contains frame and cabin dimensions. An explanation of how to read the dimensional drawing is given
~~
How To Read Frame Dimensions
• Frame dimensions are the dimensions measured by projecting certain reference points onto a plane surface.
•
• When there are no specific indications, the sta ndard pOints and dimensions are symmetrical in regard to the
center of the vehicle.
• The hypothetical lines may differ according to the vehicle model.
• The outline drawing shows the figure that projected vehicle from the upper side.
Example
DIMENSIONS
FRAME DIMENSIONS~ Shows box size
IPay Load:2t Engine:SL Mission:5MT f-- Shows applicable vehicle
Flat-plane dimensions Shows dimension
223 365 598 23.54) 84{22.99 t 1 489 358 150

'j 8.78 I{ 4.3 ) \ ( .4 )\ (19.25) (14.09l/ I{ .91
95{3.74) 27{1.06) 85{3.35) 171{6.73) 172{6.77) 131{5.16)
Shows imaginary reference line
Straight-line dimensions
8
Shows point name

/ Hole diameter Hole diameter
Point
symbol
I Designation I or boll or nut
Point
symbol
Designation
size mm{ln}
A Side member outer front end " K Front spring hanger rear
B Crossmember No.1 guide pipe ct>14.5 {O.57} L Crossmember No.4 side hole
C Side member standard hole ct>10 {O.39} M
D Air duct bracket ct>10 {O.39} N
E Front spring hanger front ct>19 {O.75} o
F Cross member No.2 side hole ct> 54 {2.13} p ct>13.7 {O.54}
G Radiator guide bracket ct>10 {O.39} Q ct>10{O.39}
H Crossmember No.3 side hole ct>40 {1.57} R Rear s rin han er rear ct>33 {1.30}
I Dumper mountinQ hole ct>13 {O.51} S Crossmember No.6 side hole ct>67 {2.64}
J Cabin mounting bracket II l;jXlo

IO.51xO.591
T
I-- Shows slot
Side member standard hole ct>19 {O.75}
DBG0980B1
00-00-2 :
J
1
I
GENERAL INFORMATION
I
How To Rear Cabin Dimensions
.r-
I:!.
e Cabin dimensions are the actual dimensions between two standard points. .
Y 9
. center of the vehicle.
_e_W--=.h_e_n_t_h_e_re_a_r_e_n_o_s_pe_c_i_fic_in_d_ic_a_t_io_n_s_, _th_e_s_t_a_n_d_ar_d_p_o_i_nt_s_a_n_d_d_im_e_n_s_io_n_s_a_r_e_s__m_m_e_tr_ic_a_l_in_re__a_r_d_to_th_e---,.'.
Example
"j
Shows vehicle section
/
I FRONT BODY~TRAIGHT-LINE DIMENSIONS (1)
mm{in}
Shows point symbol

(Right side of vehiCle)-H~~E¥;~~g=::bb(~r~~~;t~~~R~~~~1J Shows point symbol
(Left side of vehicle)
Shows detail
drawing of points
Shows point name

Hole diameter Hole diameter
Point Point
or bolt or nut Designation or bolt or nut
symbol symbol
size mm {in} size mm {in}
A Shroud panel datum hole fJ7 {O.28} D Shroud panel datum hole fJ7{O.28}
B Shroud panel datum hole fJ7 {O.28} E Shroud panel datum hole fJ6.2 {O.24}
C Shroud panel datum hole fJ7{O.28} F Crossmember datum hole fJ10 {O.39}
DBG0980B101
•
00-00-3
GENERAL INFORMATION
Symbols of Body Dimensions
• The following 8 symbols are used to iQdicate the standard points.
!
-
SYMBOL MEANING SYMBOL MEANING
-
!
® Center of circular hole (arrow only) Bolt tip
@ Center elliptical hole Center of rectangular-shaped hole
G)6iJ Notch Edge of rectangular-shaped hole
./ Panel seam, bead, etc.

MZZ2010B016
ABBREVIATION
DCFOOOOOOOOOB04
CM Control module
Ctr Center
DSC Dynamic stability control
Fr Front
HU Hydraulic unit
LH Left
M Metallic
MC Mica
RH Right
Rr Rear
00-00-4
·1 BODY & ACCESSORIES 1 QT~ 1
41------------------------------------------
BODY STRUCTURE
[DIMENSIONS] ........... 09-800
09-800 BODY STRUCTURE [DIMENSIONS]

FRAME DIMENSIONS (UNDERBODY FRONT BODY STRAIGHT-LINE
•
REGULAR CAB 2WD) ..••..••••... 09-80D-2 DIMENSIONS (2) ••••••••.••...•••• 09-80D-15
FRAME DIMENSIONS (UNDERBODY CABIN SIDE FRAME STRAIGHT-LINE
DOUBLE CAB 2WD) ••.•••••••••••. 09-80D-4 DIMENSIONS (REGULAR CAB) .••••• 09-80D-17
FRAME DIMENSIONS (UNDERBODY CABIN SIDE FRAME STRAIGHT-LINE
STRETCH CAB {WITH REAR ACCESS DIMENSIONS (DOUBLE CAB) .•••••• 09-80D-18
SYSTEM} 2WD) ...••..•••.•••••••. 09-80D-6 CABIN SIDE FRAME STRAIGHT-LINE
FRAME DIMENSIONS (UNDERBODY DIMENSIONS (STRETHC CAB
STRETCH CAB {WITH REAR ACCESS {WITH REAR ACCESS SYSTEM},
SYSTEM} HI-RIDER) .•••••••••..••• 09-80D-8 HI-RIDER) ••••••••••••••.•.•.••.•• 09-80D-19
FRAME DIMENSIONS (UNDERBODY ROOM STRAIGHT-LINE DIMENSIONS
DOUBLE CAB 4WD) ••••••••••..••• 09-80D-10 (REGULAR CAB) ••••••••••••.•••.• 09-80D-21
FRAME DIMENSIONS (UNDERBODY ROOM STRAIGHT-LINE DIMENSIONS
STRETCH CAB {WITH REAR ACCESS (DOUBLE CAB) •.••••••••••• : ••.•• 09-80D-22
SYSTEM} 4WD) ..•••.••..••..••••• 09-80D-12 ROOM STRAIGHT-LINE DIMENSIONS
FRONT BODY STRAIGHT-LINE (STRETHC CAB {WITH REAR ACCESS
DIMENSIONS (1) •..•••••••••..•... 09-80D-14 SYSTEM}, HI-RIDER) •••••....•••••• 09-80D-24
1 09-800-1
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~ Woo ::::I
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~oo 25 {4.92}
oS !!. 0
...... o Z
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~ :0
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Ol
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...... 75 {6.89}_1~"D<'" c ......
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0>
(,) 00
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1,140{44.88} IZ
en
......
00 {15.75} ':~ 'ill....
W
CO •
. 0
0> 0
-.,J
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00 {15.75} 1,1.11
n----
85 {15.16}---I1I;1o==~n-----L-----I~
o 69 {1 0.59} ~ 61 old
CD
g
85 {15.16} id bII ..
:11
I ..,.
._
-
BODY STRUCTURE [DIMENSIONS]
mm{in}
A F H J K o L P M
271
{1 D.67}
Hole diameter
Point Point
Designation or bolt or nut Designation or bolt or nut
symbol symbol
K Box bracket No.2 016 {0.63}
K' Box bracket No.2 020 {0.79}
016 x 23
L Box bracket No.3
{0.63 x 0.91}
~ Box bracket No.3 020 {0.79}
M Box mounting hole 020 {0.79}
N Front spring hanger 014 {0.55}
0 Dumper bracket M12 {0.47}
P Dumper bracket M12 {0.47}
Q Rear spring hanger 032 {1.26}
09-800-3
~~
O .-. :c
CD 9.".. a- l>
6, {9.33} t ~
0 ;
~~~~237
.... 310 {12.20} !2
0 ~ Co s:
l "?3 CD 160 {6.30} 3-' m
_ ."..CD Z
.... 125 {4.92} ~ ~
!e. 0
o z
::s en
1/1_
c:
Z
~ .... 250 {9.84} ~1~:;;JJ,883l34'70}~ ~
w "- T"Tl/ 1 ,230 {48.43} ~ OJ
!. . . . 148 {5.83} _ . •• ". • c 0
-< c
c -<
o en
~I§ 1:":1 I~I! ~ l> -I

OJ C
I\) JJ
m
1. . . . 175 {6.89}-+1&1!:\S. f6:111 EI EI 1I1:6~ -
~ .......
-c
<0 oo.J 0 m
'i\31
Co ~ ~o'1.
s:
Z
~ 81 {3.19} I, ~
1,290 {50.79} 0
~~--i ..
1::309{12.17}~' ~l ~
..... 0 ) . 400 {15.75} . l_ ......
1_ 1,130{44.49}-.....fOl
~ l::l 400 {15.75}
C11 oo.J
S I I 10
~ ~ I~ F::::'::: . ~ .. 40{44.SS1 ! ~
@ 0 a 2
~ .... 385 {15.16} • 1,024 {40.31} ~
~ 5: g
o 0
_ W _ e ~
j
mm{in}
J K P L Q M
239
{9.41}
DBG0980B004

Point Point
symbol symbol
A Cabin mounting bracket No.1 027 {1.06} K Box bracket No.1 016 {0.63}
B Bumper stay bracket 015 {0.59} K' Box bracket No.1 020 {0.79}
C Tie down hook mounting hole 013.5 {0.53} 016 x 23
L Box bracket No.3
Front suspension bracket {0.63 x 0.91}
D 025 {0.98}
tension rod ~ Box bracket No.3 020 {0.79}
E Rebound stopper bracket 012.5 {0.49} M Box mounting hole 020 {0.79}
F Front suspension bracket 016 {0.63} N Front suspension bracket 048.5 {1.91}
G Rebound stopper bracket 012.5 {0.49} 0 Front spring hanger 014 {0.55}
H Cabin mounting bracket No.2 060 {2.36} P Dumper bracket M12 {0.47}
I Cabin mounting bracket No.3 065 {2.56} Q Dumper bracket M12 {0.47}
J Cabin mounting bracket No.4 030 {1.18} R Rear spring hanger 032 {1.26}
•
1 09-800-5
o "T1 "T1
U) - ::D
~~ "tI »==
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do *"iii m
o CD
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C
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00 ~
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60 {6.30}
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........ 2S{4.92} CD en
.2l-- I\) !!!.o
(,) ~
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--
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c.u m
~ 0 OJ
4B {S.B3} 0
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m -f
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......
C
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m s:
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::D
1,224 {4B.19} IilPI Z
.... 40{9.4S}~1--"""""
»0 en
~ I\) 0
~ 0
00 ~ 1,140 {44.BB} m 0
.!:S en Z
.... en en
......
en
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~. 00 {1S.7S} • I;--- -I
(;) ~ m
!D '0
0> 0 ==
Ol -.J
I \)
0 - :i.E
~, 00 {1S.7S}--~ III c
.... BS{1S.16} " 1,140 {44.BB}
~ -
~ "1J I~I 0
.j>. ()
CO 3
oOJ
-- CO
00 ~: 69{10.S9}~ 3
."
0
<D
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Q ...... , 0
g ;1~lr_ ....... ,... .. r ............ ~ JI --2:
ro BS{1S.16} Jd# '"ro~
o
0
~L'
~ ________________________________________________________________________________________________- 4 OJ
0
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-
mm{in}
A F H J N K o L
1,645
{64.76}------I~
257
{10.12}
DBG0980B006

Point Point
symbol symbol
A Cabin mounting bracket No.1 027 {1.06} J Box bracket No.1 016 {0.63}
B Bumper stay bracket 015 {0.59} J' Box bracket No.1 020 {0.79}
C Tie down hook mounting hole 013.5 {0.53} 016 x 23
K Box bracket NO.3
Front suspension bracket {0.63 x 0.91}
D 025 {0.98}
tension rod K' Box bracket No.3 020 {0.79}
E Rebound stopper bracket 012.5 {0.49} L Box mounting hole 020 {0.79}
F Front suspension bracket 016 {0.63} M Front spring hanger 014 {0.55}
G Rebound stopper bracket 012.5 {0.49} N Dumper bracket M12 {0.47}
H Cabin mounting bracket No.2 060 {2.36} 0 Dumper bracket M12 {0.47}
I Cabin mounting bracket NO.3 065 {2.56} P Rear spring hanger 032 {1.26}
09-800-7
"""""'~',''''"'~'-,~,'''''''''''''' """"""""'~'''''~'''''~'''''~'~'''~~'~''''''~'''''~~~'''C;~'5S~~","'iilf,~~ !!jjIW&l~~~#y*~1!WI1!i!IIII1f t
o "TI "TI
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CD ~~ 'i" l>
$ '2,3:
cb I» m
o !=>I\) :;,
CD C_
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c ~ Q.
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......
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cb --
0
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...... $ ~. 0
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......
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.... W
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1,224 {48.19} IItJ ::c
1. . . . 240 {9.45}~ l> Z
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.... 0 0
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1,140{44.88} m
-0
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en en
en ......
'.... 406 {15.98} -<
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m 0 3:
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......
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(0 3 n
(Xl "-269 {1 0.59} ."
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mm{in}
,;a
•
.
r• •
A E G H o p J K
257
{10.12}
DBG0980B010

Point Point
symbol symbol
A Cabin mounting bracket No.1 027 {1.06} 016 x 23
J Box bracket No.3
B Bumper stay bracket 015 {0.59} {0.63 x 0.91}
C Tie down hook mounting hole 013.5 {0.53} J' Box bracket No.3 020 {0.79}
D Rebound stopper bracket 012.5 {0.49} K Box mounting hole 020 {0.79}
E Front suspension bracket 016 {0.63} L Front suspension bracket 016.5 {0.65}
F Rebound stopper bracket 012.5 {0.49} M Front suspension bracket 040 {1.57}
G Cabin mounting bracket No.2 060 {2.36} N Front spring hanger 014 {0.55}
"I Box bracket No.1 016 {0.63} P Dumper bracket M12 {0.47}
I' Box bracket No.1 020 {0.79} Q Rear spring hanger 032 {1.26}
09-800-9
o ~~
~ 0 -~
I :.....""" ~ l>
~ $ ~~
o - ~m
C ~~ ~ c
I .... Co ~
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3z
::::J _
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118 ~:\ ~u [ ~
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_ 1,290 {50.79}
-oZ
~~ 309 {12.17} en
...... 0> 400 {15.75} • • ","AA An' ......
406 {15.98}
(3 -.J
P -.J
$ -.J I I 10
406 {15.98} 1.1e~ IA
-1--.......1-385 {15.16}
""" 0 3
~ 269 {1 0.59} 3 g
-<en0
@ ~ ~ @
Gl :0 ::J en
~ 385 {15.16} ....... ~
o 0
~ r- g
e ~ _ e ~
•
mm{in}
•
A E G H . J p K Q L
II
fl
239
{9.41 }
DBG0980B008

Point Point
symbol symbol
K Box bracket No.3
C Tie down hook mounting hole 013.5 {0.53} K' Box bracket NO.3 020 {D.79}
D Rebound stopper bracket 012.5 {D.49} L Box mounting hole 020 {D.79}
E Front suspension bracket 016 {0.63} M Front suspension bracket 016.5 {0.65}
F Rebound stopper bracket 012.5 {D.49} N Front suspension bracket 040 {1.57}
G Cabin mounting bracket No.2 060 {2.36} 0 Front spring hanger 014 {D.55}
H Cabin mounting bracket No.3 065 {2.56} P Dumper bracket M12 {0.47}
" I Cabin mounting bracket No.4 030 {1.18} Q Dumper bracket M12 {D.47}
J Box bracket No.1 016 {D.63} R Rear spring hanger 032 {1.26}
J' Box bracket No.1 020 {D.79}
09-800-11
o(,0
~~
&, .22
o 91\)
(Xl ......
C ~
I
..... -.......
.j>.
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--
O'l
0 0
(Xl
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.j>. ......
·0
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--
~
...... Ul
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~ ro
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...... 0
(Xl
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(0
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-.
......
(0 .j>.
(0
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o ~
ro ....... ~
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ro
o __________________________________________________________________________________________________
gLI
•
•
mm{in}
A E G H o p J K
257
{10.12}
DBG0980B010

Point Point
symbol symbol
J Box bracket No.3
f_
.,
C
D
E
Tie do~n hook mounting hole
Rebound stopper bracket
Front suspension bracket
013.5 {0.53}
012.5 {0.49}
016 {0.63}
J'
K
L
Box bracket NO.3
Box mounting hole
Front suspension bracket
020 {0.79}
020 {0.79}
016.5 {0.65}
F Rebound stopper bracket 012.5 {0.49} M Front suspension bracket 040 {1.57}
G Cabin mounting bracket No.2 060 {2.36} N Front spring hanger 014 {0.55}
. I Box bracket No.1 016 {0.63} P Dumper bracket M12 {0.47}
I' Box bracket No.1 020 {0.79} Q Rear spring hanger 032 {1.26}
09-800-13
FRONT BODY STRAIGHT-LINE DIMENSIONS (1)
DCF098053020B01
mm{in}
550
~---{21.65}---~~
o. . 0 0
1,410
e
~-----------{55.51}-----------iOIoI
DBG0980B011

Point Point
symbol symbol
A Shroud panel datum hole 07 {0.28} D Shroud panel datum hole 07 {0.28}
B Shroud panel datum hole 07 {0.28} E Shroud panel datum hole 06.2 {0.24}
C Shroud panel datum hole 07 {0.28} F Crossmember datum hole 010 {0.39}
09-800-14
FRONT BODY STRAIGHT-LINE DIMENSIONS (2)
DCF098053020B02
09-800-15
~'
II
~i
111
li
II BODY STRUCTURE [DIMENSIONS]
II
r
•
it
II'I
IIi
I
11
Ii
i'
Ii
II
I'
11
1~
H
1:
I:
11
jj
Ji
Ii
I Hole diameter Point
Hole diameter
Point
Ii symbol
Designation or bolt or nut symbol
Designation or bolt or nut
Ii size mm {in} size mm {in}
11
il! Windshield garnish installation 608 x 608 E Shroud gusset datum hole 014 {0055}
A
square hole {0027 x 0027} 0602 x 8
F Cowl panel datum slot
Windshield garnish installation 608 x 608 {0024 x 0031}
B
square hole {0027 x 0027} F' Cowl panel datum hole 0602 {0024}
C Bonnet hinge installation hole 012 {0.47} G Shroud panel datum hole 010 {0039}
0 Front fender installation hole 010 {0039}
09-800-16
f

CABIN SIDE FRAME STRAIGHT-LINE DIMENSIONS (REGULAR CAB)
DCF098070010BOl
mm{in}
~.u;~~ttiTl\tt---- 1,090
{42.91}
DBG0980B015

Point Point
symbol symbol
Wheel apron panel front D Door hinge installation hole 012 {O.47}
A 012 {O.47}
datum hole E Door hinge installation hole 012 {O.47}
B Shroud panel datum hole 07 {O.28} F Side frame outer connection -
Windshield garnish installation 6.8 x 6.8 G Side frame outer datum hole 03.2 {O.13}
C square hole {O.27 x O.27}
09-800-17
CABIN SIDE FRAME STRAIGHT-LINE DIMENSIONS (DOUBLE CAB)
DCF098070010B02
mm{in} •
F G
- Fr
-- Fr
~-
T
DBG0980B018

Point Point
symbol symbol
A
Wheel apron panel front
012 {O.47}
F Side frame outer connection -
datum hole G Door hinge installation hole 012 {O.47}
B Shroud panel datum hole 07 {O.28} H Door hinge installation hole 012 {O.47}
Windshield garnish installation 6.8 x 6.8 I Side frame outer connection -
C square hole {O.27 x O.27} J Side frame outer connection -
D Door hinge installation hole 012 {O.47} K Side frame outer datum hole 03.2 {O.13}
E Door hinge installation hole 012 {O.47}
09-800-18
-.

CABIN SIDE FRAME STRAIGHT-LINE DIMENSIONS (STRETHC CAB {WITH REAR ACCESS SYSTEM}, HI-
RIDER)
DCF098070010B03
mm{in}
1,197
1--------{47.13}-------I
G
DBG0980B019
mm{in}
1,098
{43.23}
1,724
\\~~F=====~{67.87}----+-++--~~ J
1,195
{47.05}
G
DBG0980B020
09-800-19
1
1 B
o~
C
~ ~ •
fr=~
A 0
]--I
o~ t~~
0
== ~
rn --Er-
II
IA
---E! -=:: J
~ //~,l
H
~?ij I~~
G = :$ I
J
J!~t
~
:$
1=1
~
°011
II~~
i1
JL.~ :$
- Fr --Er- ~ --Er-
DBG0980B021

Point Point
symbol symbol
Wheel apron panel front F Striker installation hole 07 {O.28}
A datum hole
012 {O.47}
G Striker installation hole 013 {O.51}
B Shroud panel datum hole 07 {O.28} H Side frame outer datum hole 05 {O.20}
Windshield garnish installation 6.8 x6.8 Rear access panel hinge
C I 012 {O.47}
square hole {O.27 x O.27} installation hole
D Door hinge installation hole 012 {O.47} Rear access panel hinge
J 012 {O.47}
E Door hinge installation hole 012 {O.47} installation hole
•
09-800-20
ROOM STRAIGHT-LINE DIMENSIONS (REGULAR CAB)
DCF098070001 B01
DBG0980B022
·A
o
o
( )
- Fr 0~1 00
DBG0980B023

Point Point
symbol symbol
"
A Harness installation hole 07 {0.28} F Rear pillar inner datum hole 012 {0.47}
B Front pillar inner datum hole 010 {0.39} 08 x 12
G Rear pillar inner datum slot
C Cowl side panel datum hole 012 {0.47} {0.31 x 0.47}
Tunnel reinforcement 08.2 x7.6
D 07 {0.28} H Striker installation slot
installation hole {0.32 x 0.30}
E Rear pillar inner datum hole 012 {0.47}
09-800-21
•
ROOM STRAIGHT-LINE DIMENSIONS (DOUBLE CAB)
DCF098070001802
•
09-800-22
A E
DBG0980B025
Hole diameter
Point
Designation Designation or bolt or nut
symbol
size mm {in}
H Rear pillar inner datum hole 012 {0.47}
07x9
I Rear pillar inner datum slot
{0.28 x 0.35}
J Rear pillar inner datum hole 06 {0.24}
K Striker installation hole 010.2 {0.40}
08.2 x 7.6
L Striker installation slot
{0.32 x 0.30}
•
09-800-23
•
ROOM STRAIGHT-LINE DIMENSIONS (STRETCH CAB {WITH REAR ACCESS SYSTEM}, HI-RIDER)
DCF098070001803
•
09-800-24
DBG0980B027
Hole diameter
Point
Designation Designation or bolt or nut
symbol
size mm {in}
H Rear pillar inner datum hole 012 {0,47}
Pillar trim datum hole 06 {0.24}
010 x 20
J Pillar trim datum slot
{0.39 x 0.79}
Tunnel reinforcement datum
K 07 {0.28}
hole
M Side frame outer datum hole 010 {0.39}
09-800-25
l
DBG0980B028

Point
symbol
size mm {in}
A Harness installation hole 07 {0.28}
B Front pillar inner datum hole 010 {0.39}
C Cowl side panel datum hole 012 {0.47}
D Trim installation hole 010 {0.39}
J Pillar trim datum slot
E Striker installation hole 07 {0.28}
010 x 15 Crossmember No.3 datum
F Trim installation slot L
{0.39 x 0.59} hole
09-800-26
GENERAL INFORMATION

AIM OF DEVELOPMENT ............ 00-00-1 VEHICLE IDENTIFICATION NUMBERS
VEHICLE IDENTIFICATION NUMBER (VI N) . ........................... 00-00-12
(VIN) CODE . ..................... 00-00-12 UNITS . .......................... . 00-00-13
NEW STANDARDS . ................ . 00-00-14
AIM OF DEVELOPMENT
dcfOOOOOOOOOt01
External View
DCFOOOZWB002
Vehicle Outline
Engine
Mechanical
A roller has been adopted to the rocker arm to reduce rolling resistance. Due to this, fuel economy has
been improved. (WL-C, WE-C)
Valve lift has been increased (high lift), improving intake and exhaust efficiencies. Due to this, engine
torque and power have been improved. (WL-C, WE-C)
A timing belt auto tensioner has been adopted to reduce timing belt deterioration. (WL-C, WE-C)
A DOHC type valve system has been adopted for improved engine torque and power. (WL-C, WE-C)
Due to the bifurcated oil pan bottom, vibration in the oil pan has been reduced for improved engine noise
suppression. (WL-C, WE-C)
A hard-plastic oil strainer has been adopted for weight reduction.
A cover has been installed on the upper part of the engine for improved appearance and engine noise
suppression. (WL-C, WE-C)
A balance shaft has been adopted for reduced vibration and noise. (G
Intake/exhaust and fuel supply systems
Superior high-output, noise suppression, and low fuel consumption have been realized due to the adoption
of a direct injection type common rail. (WL-C, WE-C)
Smooth driveability has been realized due to the adoption of a variable induction turbocharger which
achieves a balance between the air charging pressure providing responsive rise from low speed and the air
charging pressure at the high speed range. (WL-C, WE-C)
" A water-cooling type EGR cooler with excellent cooling capability has been adopted for improved intake air
charging efficiency, recirculating more exhaust gas. Due to this, NOx has been reduced for improved
exhaust em~sion performance.
. ':.~-fItr--
00-00-1
GENERAL INFORMATION
--------------------------------------------------------------------------------~,
Suspension and steering
• Front suspension
The double wishbone suspension, which has I-shape lower arms and tension rods, is used for the front
suspension of 4x2 models.
The double wishbone suspension, which has A-shape lower arms, is used for the front suspension of 4x2
(Hi-Rider) and 4x4 models. A-shape lower arms have high rigidly and durability.
The torsion bar springs are used for both 4x2 and 4x4 models.
4x2
FRONT SHOCK ABSORBER
UPPER ARM
FRONT STABILZIER
TENSION ROD
LOWER ARM
DBG213ZTB001
4x2 (Hi-Rider)
UPPER ARM
FRONT STABILIZER
LOWER ARM
DBG213ZTB002
00-00-2
GENERAL INFORMATION
4x4
SHOCK ABSORBER
TORSION BAR SPRING
LOWER ARM
DBG213ZTB003
00-00-3
GENERAL INFORMATION
• Rear suspension
The rigid axle suspension with leaf spring is used for the rear suspension.
To prevent wind-up of the leaf springs during rapid acceleration or deceleration, the shock absorber on the
right side is mounted at the rear of the axle and the left one is mounted at the front of the axle, (bias ..
mount).ln order to increase the rigidity in the lateral direction, wide shackle plates are used in the frame (
mounting.
For 4x4 models, the rear springs are mounted on top of the axle housing to raise the center of gravity.
Thus, the shock absorbers attach directly to brackets welded to the axle housing.
4x2 EXCEPT
Hi-Rider
Hi-Rider, 4x4
DCF214ZTBOOl
00-00-4
GENERAL INFORMATION
• Power steering
With the adoption of an engine speed sensing power steering mechanism, handling stability has been
improved.
With the adoption, for all vehicles, of a steering column with a tilt mechanism, operability has been
improved. (Some models)
With the adoption of a steering shaft with an energy absorbing mechanism, safety has been improved.
RESERVE TANK
STEERING COLUMN AND SHAFT
POWER STEERING
OIL PUMP
STEERING GEAR AND LINKAGE
DBR614ZWB801
00-00-5
GENERAL INFORMATION
• Remote Freewheel (RFW)
The PCM receives signals from the transfer case switch and other switches. It then activates one of two
solenoids, causing a vacuum from the vacuum pump to be applied to the RFW actuator, and switching the
remote freewheel (RFW) unit to lock or free.
To prevent reduced performance of the actuator as a result of a decrease in engine vacuum or vacuum
pump, such as during acceleration or at high altitude operation, the actuation system includes a one-way
check valve.
The switching mechanism of the RFW unit is a mechanical dog clutch on the left side of the front
differential.
The RFW operation is controlled by PCM.
FRONT DIFFERENTIAL
SLEEVE
DRIVE PINION GEAR

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

RFW ACTUATOR
arnffn00000092
00-00-6a
GENERAL INFORMATION
Brakes
• A tandem-type master cylinder has been adopted, improving braking force.
• A large diameter, tandem diaphragm power brake unit has been adopted, improving braking force.
• A large diameter, ventilated disc-type front brake has been adopted, improving braking force.
• A two-piston type front disc brake caliper has been adopted, improving braking force. (Hi-Rider, 4x4)
• A wide width lining for the rear brake drum has been adopted, improving braking force.
• An Automatic adjustment mechanism rear brake (drum) has been adopted, improving serviceability.
• A vacuum pump has been adopted, improving braking force.
LOAD SENSING
PROPORTIONING VALVE (LSPV)
REAR BRAKE (DRUM)
,
FRONT BRAKE (DISC)
VACUUM PUMP
DCF411ZTBOOl (
.i
00-00-7
GENERAL INFORMATION
ABS [REAR ABS]
• The ASS is a one sensor, 1-channel control system, which provides dual control for the rear wheels.
• This system continuously monitors rear wheel speed via a sensor mounted on the differential. When the teeth
~\ on the sensor rotor, mounted on the ring gear, pass the sensor pickup, AC voltage is induced in the sensor
circuit with a frequency proportional to the average rear wheel speed. If a rear wheel is judged likely to lockup
during braking, the ASS modulates hydraulic pressure to the rear brakes, inhibiting lockup.
~ ASS CONTROL MODULE (CM)
ABSRELAY/
DCF413ATB001
00-00-8
GENERAL INFORMATION
ABS [4W-ABS]
• The ABS HU/CM, integrating both the hydraulic unit (HU) and control module (CM), has been adopted, •
resulting in size and weight reduction. I I
• Select-low controlled-4-wheel anti-lock brake system with 4-sensor and 3-channel has been adopted, and has .
the following features. i .
The integrated ABS Hydraulic Unit/Control Module (HU/CM) system is compact, lightweight and highly
reliable.
INSTRUMENT CLUSTER
G SENSOR (Hi-Rider, 4x4)
FRONT ASS WHEEL-SPEED

SENSOR
DCF413BTB001
00-00-9
GENERAL INFORMATION
Transmission
• Automatic transmission [5R55S]
Five forward speeds automatic transmission has been adopted.
~ A water-cooling type and an air-cooling type AT oil cooler has been adopted.
An adaptive learn strategy system has been adopted.
An engine-transaxle total control system has been adopted.
TSS SENSOR ISS SENSOR LOW/REVERSE

FLUID ONE-WAY CLUTCH
PUMP
OSSSENSOR
LOW/REVERSE
OVERDRIVE BRAKE
BRAKE
OVERDRIVE ONE- INTERMEDIATE CONTROL VALVE

WAY CLUTCH BRAKE BODY
arnffn00000345
00-00-10
GENERAL INFORMATION
• Manual transmission [S15M-D, S15MX-D]
A linked, triple-cone synchronizer mechanism has been adopted for 1st and 2nd gears.
A linked, double cone synchronizer mechanism has been adopted for 3rd gear.
A cam-type reverse lockout mechanism has been adopted. III
/ '
S15M-D
2ND GEAR
S15MX-D
r--------------------
COUNTER REVERSE GEAR REVERSE IDLER GEAR
____________________ JI
DCG5118T8001
Safety
• An immobilizer system has been adopted. This anti-theft device prevents the engine from being started unless
the encrypted identification code, transmitted from a special electronic chip embedded in the key, corresponds
with the identification code registered in the v e h i c l e . " ·
• Side air bags that effectively protect the chest area have been adopted for the seats.
• Pre-tensioner and load limiter mechanisms have been adopted for the seat belts.
00-00-11
GENERAL INFORMATION
• Transfer [5R55S]
A chain-type transfer drive has been adopted for 4x4 driving to improve noise suppression. In addition, the
drive sprocket, which drives the chain, rotates only during 4x4 driving to improve noise suppression during
4x2 driving.
Shifting between 4x2 HIGH, 4x4 HIGH, and 4x4 LOW is performed by the motor for improved operability.
TRANSFR
SPEED SENSOR
arnffn00000335
00-00-11a
GENERAL INFORMATION
®MNBBS1D106®123456®
====1=1-1-- l_______
. Serial No.
Algeria: ®mark
Others: Plant W=A. A. Thailand
ModelYesr 7= 2007, 8=2008, 9=2009 .. .

Production year 6= 2006, 7=2007, 8=2008 .. .
Gulf: Check Digit o to 9, X

Algeria: Plant W= A. A. Thailand
Others: No meaning o
6= F2E (2.2 EGI)
1=WL-C (2.5 L-DI)
9= WE-C (3.0 L-DI)
2= WL-3 (2.5 L Diesel-Emission Turbo)
4= WL-Turbo (2.5L Diesel turbo)
Engine type 7= G6E (2.6 EGI)
Gulf only Other

1= D= 2268-2721 kg {5001-6000 Ibs}
Gross vehicle weight 2= E= 2722-3175 kg {6001-7000 Ibs}
Gulf only Others

8= B= Regular cab.-with box
3= F= Double cab.-with box
1= Stretch cab.
2= Stretch cab.
Body style 2= (with Rear Access System) -with box
M= Thailand (for Europe (L.H.D.))

S= Japan (for Australia, General (R.H.D.),
Product sorce General (L.H.D.), Gulf)
B= Seatbelt only
D= with Air bag (Driver side)
Air bag U= with Air bag (Driver, Passenger and Side air bag)
WFO=FORD (European (L.H.D.))

MNA=FORD (Australian)
MNB=FORD (General (R.H.D.))
World manufacturer identification MNC=FORD (General (L.H.D.), Gulf)
® : This mark is used only for Algerian model, in order to identify the manufacturer.
arnffn00000261
Australian specs.
MNA BS"""
MNA OS"""
MNA LS"""
MNA US"""
arnffw00001612
00-00-12
GENERAL INFORMATION
UNITS
Electrical current A (ampere)

Electric power W (watt)
Electric resistance ohm
Electric voltage V (volt)
mm (millimeter)
Length
in (inch)
kPa (kilo pascal)
Negative pressure mmHg (millimeters of mercury)
inHg (inches of mercury)
kPa (kilo pascal)
Positive pressure kgf/cm 2 (kilogram force per square

centimeter)
psi (pounds per square inch)
N·m (Newton meter)
kgf·m (kilogram force meter)
Torque kgf·cm (kilogram force centimeter)
ft·lbf (foot pound force)
in·lbf (inch pound force)
L (liter)
US qt (U.S. quart)
Imp qt (Imperial quart)
Volume ml (milliliter)
cc (cubic centimeter)
cu in (cubic inch)
fI oz (fluid ounce)
g (gram)
Weight
oz (ounce)
Conversion to SI Units (Systeme International d'Unites)

• All numerical values in this manual are based on 81 units. Numbers shown in conventional units are converted
from these values.
Rounding Off
• Converted values are rounded off to the same number of places as the 81 unit value. For example, if the 81 unit
value is 17.2 and the value after conversion is 37.84, the converted value will be rounded off to 37.8.
Upper and Lower Limits

• When the data indicates upper and lower limits, the converted values are rounded down if the 81 unit value is
an upper limit and rounded up if the 81 unit value is a lower limit. Therefore, converted values for the same 81
unit value may differ after conversion. For example, consider 2.7 kgf/cm 2 in the following specifications:
210-260 kPa {2.1-2.7 kgf/cm 2 , 30-38 psi}

270-310 kPa {2.7-3.2 kgf/cm 2 , 39-45 psi}
• The actual converted values for 2.7 kgf/cm 2 are 265 kPa and 38.4 psi. In the first specification, 2.7 is used as
an upper limit, so the converted values are rounded down to 260 and 38. In the second specification, 2.7 is
used as a lower limit, so the converted values are rounded up to 270 and 39.
00-00-13
GENERAL INFORMATION
NEW STANDARDS
dcfOOOOOOOOOt05
• Following is a comparison of the previous standard and the new standard.

New Standard Previous Standard
/
Abbrevi- Abbrevi- Remark \.
Name Name
ation ation
AP Accelerator Pedal - Accelerator Pedal
APP Accelerator Pedal Position - Accelerator Pedal Position
ACL Air Cleaner - Air Cleaner
AlC Air Conditioning - Air Conditioning
BARO Barometric Pressure - Atmospheric Pressure
B+ Battery Positive Voltage VB Battery Voltage
- Brake Switch - Stoplight Switch
- Calibration Resistor - Corrected Resistance #6
CMP sensor Camshaft Position Sensor - Crank Angle Sensor
LOAD Calculated Load Voltage - -
CAC Charge Air Cooler - Intercooler
CLS Closed Loop System - Feedback System
CTP Closed Throttle Position - Fully Closed
CPP Clutch Pedal Position - Clutch Position
CIS Continuous Fuel Injection System EGI Electronic Gasoline Injection System
CS sensor Control Sleeve Sensor CSP sensor Control Sleeve Position Sensor #6
CKP sensor Crankshaft Position Sensor - Crank Angle Sensor 2
DLC Data Link Connector - Diagnosis Connector
DTM Diagnostic Test Mode - Test Mode #1
DTC Diagnostic Trouble Code(s) - Service Code(s)
DI Distributor Ignition - Spark Ignition
DLI Distributorless Ignition - Direct Ignition
EI Electronic Ignition - Electronic Spark Ignition #2
ECT Engine Coolant Temperature - Water Thermo
EM Engine Modification - Engine Modification
- Engine Speed Input Signal - Engine RPM Signal
EVAP Evaporative Emission - Evaporative Emission
EGR Exhaust Gas Recirculation - Exhaust Gas Recirculation
FC Fan Control - Fan Control
FF Flexible Fuel - Flexible Fuel
4GR Fourth Gear - Overdrive
- Fuel Pump Relay - Circuit Opening Relay #3
FSO
Fuel Shut Off Solenoid FCV Fuel Cut Valve #6
solenoid
GEN Generator - Alternator
GND Ground - Ground/Earth
H02S Heated Oxygen Sensor - Oxygen Sensor With heater
lAC Idle Air Control - Idle Speed Control
- IDM Relay - Spill Valve Relay #6
- Incorrect Gear Ratio - -
- Injection Pump FIP Fuel Injection Pump #6
- InputlTurbine Speed Sensor - Pulse Generator
IAT Intake Air Temperature - Intake Air Thermo
KS Knock Sensor - Knock Sensor
MIL Malfunction Indicator Lamp - Malfunction Indicator Light
MAP Manifold Absolute Pressure - Intake Air Pressure
MAF Mass Air Flow - Mass Air Flow
MAF sensor Mass Air Flow Sensor - Airflow Sensor
MFL Multiport Fuel Injection - Multiport Fuel Injection
OBD On-Board Diagnostic - Diagnosis/Self Diagnosis
OL Open Loop - Open Loop
00-00-14
GENERAL INFORMATION

Abbrevi- Abbrevi- Remark
Name Name
ation ation
- Output Speed Sensor - Vehicle Speed Sensor 1
OC Oxidation Catalytic Converter - Catalytic Converter
02S Oxygen Sensor - Oxygen Sensor
PNP Park/Neutral Position - Park/Neutral Range
PID Parameter Identification - Parameter Identification
- PCM Control Relay - Main Relay #6
PSP Power Steering Pressure - Power Steering Pressure
PCM Powertrain Control Module ECU Engine Control Unit #4
- Pressure Control Solenoid - Line Pressure Solenoid Valve
Pulsed
PAIR Pulsed Secondary Air Injection - Secondary Air Injection System
injection
- Pump Speed Sensor - NE Sensor #6
RAM Random Access Memory - -
Injection
AIR Secondary Air Injection - Secondary Air Injection System with air
pump
SAPV Secondary Air Pulse Valve - Reed Valve
SFI Sequential Multipoint Fuel Injection - Sequential Fuel Injection
- 1-2 Shift Solenoid Valve
- Shift Solenoid A
- Shift A Solenoid Valve
- Shift Solenoid B
- Shift B Solenoid Valve
- Shift Solenoid C - 3--4 Shift Solenoid Valve
3GR Third Gear - 3rd Gear
TWC Three Way Catalytic Converter - Catalytic Converter
TB Throttle Body - Throttle Body
TP Throttle Position - -
TP sensor Throttle Position Sensor - Throttle Sensor
TCV Timer Control Valve TCV Timing Control Valve #6
TCC Torque Converter Clutch - Lockup Position
Transmission (Transaxle) Control
TCM
Module
- EC-AT Control Unit
Transmission (Transaxle) Fluid

- - ATF Thermosensor
Temperature Sensor
TR Transmission (Transaxle) Range - Inhibitor Position
TC Turbocharger - Turbocharger
VSS Vehicle Speed Sensor - Vehicle Speed Sensor
VR Voltage Regulator - IC Regulator
VAF sensor Volume Air Flow Sensor - Air Flow Sensor
Warm Up Three Way Catalytic
WUTWC - Catalytic Converter #5
Converter
WOT Wide Open Throttle - Fully Open
#1: Diagnostic trouble codes depend on the diagnostic test mode

#2: Controlled by the PCM
#3:'ln some models, there is a fuel pump relay that controls pump speed. That relay is now called the fuel pump
relay (speed).
#4: Device that controls engine and powertrain
#5: Directly connected to exhaust manifold
#6: Part name of diesel engine
00-00-15
ENGINE
I(lll
OUTLINE ................. 01-00 INTAKE-AIR SYSTEM
ON-BOARD DIAGNOSTIC [WL-C, WE-C] ............. 01-13B
[WL-3] . . . . . . . . . . . . . . . . . . 01-02A FUEL SYSTEM [WL-3] ....... 01-14A
ON-BOARD DIAGNOSTIC FUEL SYSTEM
[WL-C, WE-C] . . . . . . . . . . . . 01-028 [WL-C, WE-C] ............. 01-14B
MECHANICAL [WL-3] ....... 01-10A EXHAUST SYSTEM [WL-3] ... 01-15A
MECHANICAL . EXHAUST SYSTEM
[WL-C, WE-C] ............ 01-108 [WL-C, WE-C] ............. 01-15B
LUBRICATION [WL-3] ....... 01-11A EMISSION SYSTEM [WL-3] ... 01-16A
LUBRICATION EMISSION SYSTEM
[WL-C, WE-C] . . . . . . . . . . . . 01-11 B [WL-C, WE-C] ............. 01-16B
COOLING SYSTEM [WL-3]. . . 01-12A CHARGING SYSTEM
COOLING SYSTEM [WL-3, WL-C, WE-C] ....... 01-17
[WL-C, WE-C] ............ 01-128 STARTING SYSTEM
INTAKE-AIR SYSTEM [WL-3, WL-C, WE-C] ....... 01-19
[WL-3] . . . . . . . . . . . . . . . . . . 01-13A CONTROL SYSTEM [WL-3] ... 01-40A
CONTROL SYSTEM
[WL-C, WE-C] ............. 01-40B
01-00 OUTLINE
ENGINE ABBREViATIONS ........... 01-00-1 ENGINE SPECIFICATION [WL-3] ..... . 01-00-3
ENGINE FEATURES ENGINE SPECIFICATION
[WL-3, WL-C, WE-C]. . . . . . . . . . . . . .. 01-00-2 [WL-C, WE-C] . ................... . 01-00-5
ENGINE ABBREVIATIONS
dcf01000200Ot01
ABDC After Bottom Dead Center

ABS Antilock Brake System
ACC Accessories
ATDC After Top Dead Center
BBDC Before Bottom Dead Center
BDC Bottom Dead Center
BTDC Before Top Dead Center
CAN Controller Area Network
CCM Comprehensive Component Monitor
CM Control Module
DC Drive Cycle
DLC-2 Data Link Connector-2
DOHC Double Overhead Camshaft
DSC Dynamic Stability Control
EX Exhaust
FFD Freeze Frame Data
HU Hydraulic Unit
IN Intake
KOEO Key On Engine Off
KOER Key On Engine Running
M Motor
MRE Magneto Resistance Element
01-00-1
OUTLINE
MT Manual Transmission
PATS Passive Anti-theft System
OFF Switch on
ON switch off (
PC Pending Code
PCV Positive Crankcase Ventilation
PID Parameter Identification
PIS Power Steering
SOHC Single Overhead Camshaft
SST Special Service Tool
TDC Top Dead Center
VBC Variable Boost Control
ENGINE FEATURES [WL-3, WL-C, WE-C]

dcfD1000200Qt02
Mechanical
• Coated pistons have been adopted (WL-C, WE-C)
Improved engine performance • Swirl type combustion chamber (WL-3)
• DOHC with 4 valves per cylinder (WL-C, WE-C)
• 3 valves per cylinder (WL-3)
• An eight counter weight crankshaft has been adopted
Reduced engine noise and • A crankshaft pulley cover has been adopted (WL-C, WE-C)
vibration • An engine cover with insulator has been adopted (WL-C, WE-C)
• Full-floating cylinder head cover mounting
• Torsional damper pulley
Improved serviceability • An auto tensioner that automatically adjusts the timing belt tension has been adopted
(WL-C, WE-C)
Improved design • ,An engine cover has been adopted (WL-C, WE-C)
Lubrication
• Gear type oil pump adopted
Improved lubricity • Oil jet valves adopted
• Water-cooled type oil cooler adopted
Reduced weight • Plastic oil strainer adopted
Reduced engine noise • Oil pan baffle plate adopted (WL-C, WE-C)
Cooling System
Reduced weight • Down flow type radiator with aluminum core and plastic tank adopted
Miniaturization • Built-in type water pump adopted
Reduced noise • Thermo-modulation type cooling fan adopted
Improved serviceability • Longer-life new engine coolant (type FL22) adopted
Intake air System

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

purification • Small size turbocharge has been adopted (WL-3)
Fuel System
Improved emission gas
purification • Electronic control type fuel injection pump adopted
Exhaust gas purification • Common rail injection system adopted (WL-C, WE-C)
Emission System
• EGR system adopted
Improved exhaust gas purification • EGR cooler adopted
• Oxidation catalytic converter adopted
Improved reliability • Rollover valve adopted
Charging System
IImproved reliability I • Generator with built-in battery sensing type IC regulator adopted
01-00-2
OUTLINE
Starting System
IImproved startability I• Reduction type starter adopted
Control System
Improved emission gas • Intake shutter valve control adopted (WL-C, WE-C)
purification • Fuel injection control changed
• EGR control adopted
ENGINE SPECIFICATION [WL-3]

dcf01000200Ot03
Specification
Specifications
Item
WL-3
MECHANICAL
Type Diesel, 4-cycle
Cylinder arrangement and number In-line, 4 cylinder
Combustion chamber Swiri type
Valve system SOHC, timing gear and belt driven, 12-valve
Displacement (ml {cc, cu in}) 2,499 {2,499, 152.4}
Bore x stroke (mm {in}) 93.0 x 92.0 {3.66 x 3.62}
Compression ratio 21.6
Compression pressure (kPa {kgf/cm2, psi} [rpm]) 2,942 {30.0, 427} [200]
Open BTDC (0) 8
IN
Close ABDC (0) 23
Valve timing
Open BBDC (0) 61
EX
Close ATDC (0) 9
Valve clearance IN 0.05-0.15 {0.0020-0.0059}
(mm {in})
[Engine cold] EX 0.15-0.25 {0.0060-0.0098}
LUBRICATION SYSTEM
Type Force-fed type
Oil pressure (reference value) 2
(kPa {kgf/cm , psi} [rpm]) 410-570 {4.19-5.81 , 59.6-82.6} [2,500]
[after warm up]
Type Gear type
Oil pump Relief valve opening pressure
(reference value) (kPa {kgf/cm 2, psi}) 580-700 {5.9-7.1, 84.1-1 01.5}
Oil cooler Type Water-cooled

Type Full-flow, paper element
Oil filter
Bypass pressure (kPa {kgf/cm 2 , psi}) 80-120 {0.82-1.22, 11.6-17.4}
Oil capacity Total (dry engine) (L {US qt, Imp qt}) 6.7 {7.1, 5.9}
(approx. Oil replacement (L {US qt, Imp qt}) 5.5 {5.8, 4.8}
quantity) Oil and oil filter replacement (L {US qt, Imp qt}) 6.2 {6.6, 5.5}
COOLING SYSTEM
Type Water-cooled, forced circulation
Coolant capacity (approx. quantity) (L {US qt, Imp qt}) 8.8 {9.3, 7.7}
Water pump Type Centrifugal, V-belt driven
Type Wax, bottom-bypass
Opening temperature (OC {OF}) 80-84 {176-183}
Thermostat
Full-open temperature (OC {OF}) 95 {203}
Full-open lift (mm {in}) 8.5 {0.33} or more
Radiator Type Corrugated fin
Cap valve
Cooling system cap opening (kPa {kgf/cm2, psi}) 93.2-122.6 {0.95-1.25, 13.5-17.8}
pressure
Type Thermo-modulation type
Cooling fan Number of blades 10
Outer diameter (mm {in}) 440 {17.3}
01-00-3
OUTLINE
Specifications
Item
WL-3
INTAKE AIR SYSTEM
Turbocharger type Small size turbocharger i .
Air cleaner element Dry type (Non-woven fabric)
Glow plug type Ceramic type
FUEL SYSTEM
Fuel injection pump Bosch VE distributor (Electronic control)
Fuel tank capacity (reference) (L {US gal, Imp gal}) 63 {17, 14}*1, 70 {18, 15}*2
EMISSION SYSTEM
EGR valve type Vacuum
Catalytic converter type Oxidation catalytic converter
CHARGING SYSTEM
Voltage (V) 12
Battery Type and capacity
(A·h) 65031 R (56)
(5-hour rate)
Output (V-A) 12-70
Generator Regulated voltage (V) 14.1-14.7
Self diagnosis function Equipped
STARTING SYSTEM
Type Coaxial reduction
Starter
Output (kW) 2.2
CONTROL SYSTEM
IAT sensor No.2 (Inside MAF) Thermistor
MAF sensor Hot-wire
IAT sensor No.1 Thermistor
Boost sensor Piezoelectric element
ECT sensor Thermistor
CKP sensor Magnetic pickup
APP sensor Potentiometer
EGR valve position sensor Potentiometer
BARO sensor (built into PCM) Piezoelectric element
Fuel temperature sensor Thermistor
CS sensor Magnetic pickup
Timer position sensor Magnetic pickup
Fuel pump speed sensor Magnetic pickup
Neutral switch ON/OFF
CPP switch ON/OFF
Idle switch ON/OFF
*1 : Double cab, freestyle cab

*2 : Regular cab
Recommended engine oil

Item Specification
Grade API CD/CE/CF--4 or ACEA B1/B3/B5 :'
Viscosity (SAE) 5W-30, 10W-30
01-00-4
OUTLINE
ENGINE SPECIFICATION [WL-C, WE-C]
dcf010002000to4
Specification
Item
Compression pressure
IN
Valve timing
EX
0.10-0.16 mm {0.0040- 0.10-0.16 mm {0.0040-
IN (mm {in})
Valve clearance 0.0062 in} 0.0062 in}
[engine cold] 0.17-0.23 mm {0.0067- 0.17-0.23 mm {0.0067-
EX (mm {in})
0.0090 in} 0.0090 in}
Oil pressure (reference value) (kPa {kgf/cm 2 , psi} 410-570 {4.19-5.81, 59.6-82.6} [2,500]
[after warm up]
Oil pump
(kPa {kgf/cm 2 , psi}) 580-700 {5.9-7.1, 84.1-101.5}
80-120 {0.82-1.22, 11.6-17.4}
7.0 {7.4, 6.2}
Centrifugal, V-belt driven
( C { F}) 80-84 {176-183}

Thermostat
95 {203}
Cooling system cap 93.2-122.6 {0.95-1.25, 13.5-17.8}
Cooling fan
(mm {in}) 450 {17.7}
01-00-5
OUTLINE
Specifications
Item
WL-C I WE-C
Air cleaner element Dry type
Glow plug type Stainless type (
FUEL SYSTEM
Supply pump Electronic control
Fuel injector Electromagnetic control
Fuel tank capacity
(L {US gal, Imp gal}) 70 {18, 15}
(reference)
EMISSION SYSTEM
CHARGING SYSTEM
Voltage (V) 12
8attery Type and capacity
(A-Ji 65D31R (56) 95D31 R (64)
(5-hour rate) I
Output (V-A) 12-70
Generator Regulated voltage (V) 14.1-14.7
Self diagnosis function Equipped
STARTING SYSTEM
Type Coaxial reduction
Starter
Output (kW) 2.2
CONTROL SYSTEM
MAF sensor Hot-wire
800st sensor Piezoelectric element
CMP sensor Hall element type
8ARO sensor (built into PCM) Piezoelectric element
Fuel pressure sensor Piezoelectric element
CPP switch ON/OFF
Idle switch ON/OFF

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

ON-80ARD DIAGNOSTIC OUTLINE DTC DETECTION LOGIC AND
[WL-C, WE-C] .................... 01-028-1 CONDITIONS [WL-C, WE-C] ......... 01-028-9
DIAGNOSTIC SYSTEM PID/DATA MONITOR AND RECORD
WIRING DIAGRAM [WL-C, WE-C] .... 01-028-2 [WL-C, WE-C] .................... 01-028-15
DTC TEST MODE [WL-C, WE-C] ...... 01-028-6 SIMULATION TEST [WL-C, WE-C] ..... 01-028-16
KOEO/KOER SELF-TEST
[WL-C, WE-C] ..................... 01-028-16
ON-80ARD DIAGNOSTIC OUTLINE [WL-C, WE-C]

Features
Improved serviceability • DTCs adopted
• KOEO/KOER self-test function adopted
• PID/DATA monitor function adopted
• Simulation test function adopted
810ck Diagram
PCM
OBD SYSTEM
r-------------------------------------------
I
I
I MALFUNCTION
I
I
I
I
:> INDICATION
FUNCTION
I
MIL
I
I
U {}
TESTER
MEMORY
FUNCTION
I :> COMMUNICATION 'I DLC-2 (CAN) I
~
FUNCTION
{} V B
I M-MDS
I
I
DETECTION PID DATA SIMULATION
I
I
FUNCTION MONITOR TEST
I
I
FUNCTION FUNCTION
I
I
I
I -
A A
~---11--- -------- ------------ ------
FAIL-SAFE
FUNCTION
D
INPUT DEVICE
Q
L-- ~
ENGINE CONTROL SYSTEM

V
Q OL1TPL1T DEVICE
D8G1028T8001
01-028-1
DIAGNOSTIC SYSTEM WIRING DIAGRAM [WL-C, WE-C]
dcf010200000l14
With Immobilizer System
-f--t-+LOCK
ACC
IG1
-I::--t---{E
IG2
STA DLC
IG-
FEN
KLN
TEN
F
DLC-2
KLN
' - - - - I TEN
PCM
(BUILT INTO
GLOW INDICATOR
LIGHT .,---.j--------1I----------f BARO SENSOR)
VEHICLE
SPEED SIGNAL
FUEL
INJECTOR
INSTRUMENT CLUSTER NO.4
FUEL
INJECTOR
NO.3
FUEL
INJECTOR
NO.2
FUEL
INJECTOR
IAT NO.1
SENSOR
NO.2
DBG102BWBY01
01-028-2
APP
SENSOR
FUEL PRESSURE
SENSOR
BOOST
SENSOR
CMPSENSOR
ECT
SENSOR I '-'-+--_~
FUEL
CKP SENSOR
TEMPERATURE
SENSOR
EGRVALVE
POSITION
SENSOR PCM
F
Tl--+--o 0--+--1-... GLOW
PLUG
BLOWER ' - - - - '
RELAY
MOTOR
REFRIGERANT
PRESSURE - ---------------------------,
SWITCH (LOW) VARIABLE SWIRL :
~r--~~ o-~~~ CONTROL :
SOLENOID VALVE :
AlC
COMPRESSOR
AlC RELAY
AlC
:SWITCH
: THERMO SWITCH
,,
'•••••••••••••••• WITH AlC················ ~
DBG102BWBY02
01-028-3
Without Immobilizer System
.J-4----(E
STA DLC
r------~-~--~~-------~~---------~IG-
FEN
KLN
TEN
DLC-2
'------l KLN
'-----iTEN
PCM
(BUILT INTO
GLOW INDICATOR
BARO SENSOR)
LIGHT
VEHICLE
SPEED SIGNAL
FUEL
INJECTOR
FUEL
INJECTOR
NO.3
FUEL
INJECTOR
NO.2
FUEL
INJECTOR
NO.1
DBG102BWBY03
01-028-4
RFWLOCK
SOLENOID
APP 1---1--+"" VALVE
SENSOR
RFW FREE
SOLENOID
1----+"" VALVE
FUEL PRESSURE
SENSOR
BOOST
SENSOR
CMPSENSOR
ECT
SENSOR ~I----r
FUEL CKPSENSOR
TEMPERATURE
SENSOR
EGRVALVE
POSITION
SENSOR PCM
D--+--o o--+--+-... GLOW

PLUG
BLOWER ' - - - - - '
RELAY
MOTOR
.~~------ --------------------------------
REFRIGERANT
PRESSURE .. .. ................................................ .. -,
SWITCH (LOW) VARIABLE SWIRL :
~r--~~ O-~~~ CONTROL I
SOLENOID VALVE :
AlC I
I
COMPRESSOR I
. . . . . . oo ...
AlC RELAY
THERMO SWITCH
- - - - - - - - - - - - - - • WITH AlC - - - - - - - - - - - - - - - - ~
DBG102BWBY02
01-028-5
DTC TEST MODE [WL-C, WE-C]
dcf01020000ot15
Sending Diagnostic Data

PID data monitor
• The PID data monitor items are shown below.
PID data monitor table
-: Not applicable
Full names Unit
Monitor status since DTCs cleared -
Calculated LOAD value %
Engine coolant temperature °C I of
Intake manifold absolute pressure kPa
Engine speed rpm
Vehicle speed km/h I mph
Intake air temperature °C I of
Air flow rate from mass air flow sensor gls
OBD requirement according to vehicle design -
Time Since Engine Start s
Distance travelled while MIL is activated km I miles
Fuel rail pressure kPa
EGR valve control signal %
Number of warm-ups since DTCs cleared -
Distance travelled since DTCs cleared km I miles
Barometric Pressure kPa
PCM power supply voltage V
Ambient air temperature °C I of
Accelerator pedal position (sensor No.1) %
Sending Freeze Frame Data

• The Freeze Frame Data monitor items are shown below.
Freeze Frame Data monitor table
-: Not applicable
Full names Unit
DTC that caused required Freeze Frame Data storage -
Calculated LOAD value %
Engine coolant temperature °C I of
Intake manifold absolute pressure kPa
Engine speed rpm
Vehicle speed· km/h I mph
Intake air temperature °C I of
Air flow rate from mass air flow sensor gls
Fuel rail pressure kPa
Barometric Pressure kPa
01-028-6
Sending Emission-related Malfunction Code
The DTCs are shown below.
Self-test
MIL DC *1
Variable boost control (VBC) solenoid valve circuit rangel

POO46 performance malfunction
ON C/O/R
Variable boost control (VBC) solenoid valve control circuit low
POO47 input
ON C/O/R
Variable boost control (VBC) solenoid valve control circuit high
POO48 input
ON C/O/R
01-028-7
Self-test Memory
DTC C ondition MIL DC type*1 function
P0403 EGR solenoid valve circuit malfunction ON 1 CIOIR
P0404 EGR valve stuck ON 2 CIR
P0405 EGR valve position sensor circuit low input ON 1 CIOIR
P0406 EGR valve position sensor circuit high input ON 1 CIOIR
P0489 EGR solenoid valve control circuit low input ON 1/2 CIO
P0490 EGR solenoid valve control circuit high input ON 1/2 CIO
P0500 VSS circuit malfunction ON 2 C
P0562 Battery voltage low input ON 1 ClaiR
P0563 Battery voltage high input ON 1 ClaiR
P0602 PCM programming error ON 1 a
P0606 PCM malfunction ON 1 ClaiR
P0607 PCM performance problem ON 1/2 ClaiR
P0610 PCM vehicle options error ON 1 a
P0627 Fuel metering valve control circuit open ON 1 CIR
P0628 Fuel metering valve control circuit low input ON 1 CIR
P0629 Fuel metering valve control circuit high input ON 1 C/R
P0642 Fuel pressure sensor and boost sensor 5 V circuit low input ON 1 ClaiR
P0643 Fuel pressure sensor and boost sensor 5 V circuit high input ON 1 ClaiR
P0652 CMP sensor and APP sensor 5 V circuit low input ON 1 ClaiR
P0653 CMP sensor and APP sensor 5 V circuit high input ON 1 CIOIR
P0660 Intake shutter solenoid valve (half) control circuit open ON 1 cia
P0661 Intake shutter solenoid valve (half) control circuit low input ON 1 CIO
P0662 Intake shutter solenoid valve (half) control circuit high input ON 1 cia
P0663 Intake shutter solenoid valve (full) control circuit open ON 1 CIO
P0664 Intake shutter solenoid valve (full) control circuit low input ON 1 CIO
P0665 Intake shutter solenoid valve (full) control circuit high input ON 1 CIO
P0685 Main relay control circuit open - - -
P0698 EGR valve position sensor 5 V circuit low input ON 1 C/O/R
P0699 EGR valve position sensor 5 V circuit high input ON 1 CIOIR
P1196 Key off voltage high input - - -
P1259 IMMOBILIZER to PCM signal error - - cia -
P1260 Theft detected Vehicle immobilizer - - CIO -
P1391 Glow plug control circuit low input ON 1 cia
P1392 Glow plug control circuit high input ON 1 cia
P1528 Exhaust shutter solenoid valve circuit problem - 1 CIO -
P1602 Immobilizer/PCM communication error - - cia -
P1603 10 Number Unregistered - - cia -
P1604 Code word unregistered - - CIO -
P1621 Immobilizer code word does not match - - CIO -
P1622 Immobilizer 10 does not match - - CIO -
P1623 Immobilizer code wordllO number write failure - - CIO -
P1624 Anti-theft system - - cia -
P1675 Injection quantity adjustment value writing error ON 1 a
P1676 Injection quantity adjustment value checksum error ON 1 a
P2008 Variable swirl control (VSC) solenoid valve circuit open ON 1 cia
P2009 Variable swirl control (VSC) solenoid valve circuit low input ON 1 CIO
P2010 Variable swirl control (VSC) solenoid valve circuit high input ON 1 CIO
Accelerator pedal position (APP) sensor No.1 INo.2 voltage
P2135 ON 1 ClaiR
correlation problem
Accelerator pedal position (APP) sensor No.1/idle switch voltage
P2136 ON 1 CIOIR
correlation problem
P2143 EGR control solenoid valve control circua open ON 1/2 cia
P2144 EGR control solenoid valve control circuit low input ON 1/2 C/O/R
P2145 EGR control solenoid valve control circuit high input ON 1/2 ClaiR
01-028-8
Self-test Memory
DTC Condition MIL DC
type*1 function
P2146 Fuel injector No.1 and No.4 power supply circuit malfunction ON C/R
P2147 Fuel injector No.1 and No.4 power supply circuit low input ON C/R
P2148 Fuel injector No.1 and No.4 power supply circuit high input ON C/R
P2149 Fuel injector No.2 and NO.3 power supply circuit malfunction ON C/R
P2150 Fuel injector No.2 and NO.3 power supply circuit low input ON C/R
P2151 Fuel injector No.2 and NO.3 power supply circuit high input ON C/R
P2227 BARO sensor circuit range/performance malfunction ON C
P2228 BARO sensor circuit low input ON C/O/R
P2229 BARO sensor circuit high input ON C/O/R
P2263 Air charging system performance malfunction C
P2530 PCM (engine switch circuit) malfunction ON 0
*1 : C; CMDTe self test, 0; KOEO self test, R; KOER self test
Sending Continuous Monitoring System Test Results

These appear when a problem is detected in a monitored system.
1-drive cycle type

If any problems are detected in the first drive cycle, confirmed DTCs will be stored in the peM memory.
2-d rive cycle type

The code for a failed system is stored in the PCM memory in the first drive cycle. If the problem is not found in
the second drive cycle, the PCM determines that the system returned to normal or the problem was mistakenly
detected, and deletes the pending code. If the problem is found in the second drive cycle too, the PCM
determines that the system has failed, and stores the DTCs.
After pending codes are stored, if the PCM determines that the system is normal in any future drive cycle, the
PCM deletes the pending codes.
DTC DETECTION LOGIC AND CONDITIONS[WL-C, WE-C]

id0102c4100300
P0016 CKP-CMP correlation
The PCM monitors the input pulses from the CKP and CMP sensors. If the pick-up timing input pulses do not
match each other, the peM determines that the camshaft position does not coincide with the crankshaft
position.
P0045 Variable boost control (VeC) solenoid valve control circuit open
The PCM monitors the VBC solenoid valve control signal. If the VBC solenoid valve control voltage is less than
5 V for 2 s when the VBC solenoid valve is off, the PCM determines that there is a VBC solenoid valve control
circuit malfunction (open circuit).
P0046 Variable boost control (VeC) solenoid valve circuit range/performance malfunction
The PCM monitors the driver IC temperature of the VBC solenoid valve. If the temperature of the VBC solenoid
valve driver IC in the PCM exceeds 150 C{320 F} while the VBC solenoid valve is operating, the PCM
determines that there is a VBC solenoid value malfunction.
P0047 Variable boost control (VeC) solenoid valve control circuit low input
The PCM monitors the VBC solenoid valve control signal. If the PCM turns VBC solenoid valve off but the
voltage at PCM terminal 178 still remains low, the PCM determines that the VBC solenoid valve circuit has a
malfunction (circuit short to ground).
P0048 Variable boost control (VeC) solenoid valve control circuit high input
The peM monitors the VBC solenoid valve control signal. If the peM turns VBC solenoid valve on but the
current at peM terminal 178 still remains high, the PCM determines that the VBC solenoid valve circuit has a
malfunction (circuit short to power supply).
P0088 Fuel pressure system too high
The PCM monitors the fuel pressure in the common rail from the fuel pressure sensor while the engine is
running. If the fuel pressure is more than the preprogrammed criteria, the PCM determines that the fuel
pressure is too high.
P0093 Fuel system leak detection
The peM monitors the fuel pressure in the common rail from the fuel pressure sensor while the engine is
running. If the fuel pressure is lower than the preprogrammed criteria, the PCM determines that there is
leakage in the fuel system.
01-028-9
P0097 Intake air temperature (IAT) sensor No.2 circuit low input
The PCM monitors the input signal from intake air temperature sensor NO.2. If the voltage from intake air
temperature sensor No.2 is less than 0.1 V for 2 s, the PCM determines that there is a malfunction in the
intake air temperature sensor No.2 circuit.
P0098 Intake air temperature (I AT) sensor No.2 circuit high input (.
The PCM monitors the input signal from intake air temperature sensor NO.2. If the voltage from intake air
temperature sensor No.2 is more than 4.6 V for 1 s, the PCM determines that there is a malfunction in the
P0101 Mass airflow (MAF) sensor range/performance malfunction
The PCM monitors the ratio between calculated air mass flow and actual air mass flow under the programmed
condition.
If the ratio is more than or less than the programmed criteria the PCM determine that there is a malfunction in
the MAF sensor.
P0102 Mass airflow (MAF) sensor circuit low input
The PCM calculates the intake air flow amount based on the airflow sensor. If the calculated intake air flow
amount is below 0.44 g/s {0.058 Ib/min} for 2.0 s while the engine is running, the PCM determines that the
airflow sensor signal input is low.
P0103 Mass airflow (MAF) sensor circuit high input
The PCM calculates the intake air flow amount based on the airflow sensor. If the calculated intake air flow
amount is above 170 g/s {22 Ib/min} for 1.5 s while driving other than under a fully open throttle condition, and
the fuel injection quantity based on the engine speed is below the specification, the PCM determines that the
airflow sensor signal input is high.
P0106 Boost sensor range/performance malfunction
The PCM monitors and compares the intake manifold internal pressure via the boost sensor with the
atmospheric pressure via the barometric pressure sensor (built into PCM) while the engine is not running. lithe
difference of these pressure is above 11 kPa {0.11 bar, 1.6 psi}, the PCM determines that there is a boost
sensor characteristic malfunction.
P0107 Boost sensor circuit low input
The PCM monitors the input signal from the boost sensor. If the voltage from the boost sensor is less than 0.24
V for 2.0 s, the PCM determines that there is a malfunction in the boost sensor circuit.
P0108 Boost sensor circuit high input
The PCM monitors the input signal from the boost sensor. If the voltage from the boost sensor is more than 4.9
V for 1.0 s, the PCM determines that there is a malfunction in the boost sensor circuit.
P0111 Intake air temperature (IAT) sensor No.1 range/performance malfunction
The PCM monitors the input signal from the IAT sensor No.1. If the difference between the maximum and
minimum value of the IAT sensor No.1 is less than 1 °C {1.8 OF}, the PCM determines that there is a
malfunction in the IAT sensor NO.1.
The PCM monitors the input signal from IAT sensor NO.1. If the voltage from IAT sensor No.1 is less than 0.14
V for 2.0 s, the PCM determines that there is a malfunction in the IAT sensor No.1 circuit.
P0113 Intake air temperature (IAT) sensor No.1 circuit high input
The PCM monitors the input signal from IAT sensor NO.1. If the voltage from IAT sensor No.1 is more than 4.90
V for 1.0 s, the PCM determines that there is a malfunction in the IAT sensor No.1 circuit.
P0116 Engine coolant temperature (ECT) sensor range/performance malfunction
Minimum engine coolant temperature rise is not achieved within the specified time limit from when the engine
was started.
P0117 Engine coolant temperature (ECT) sensor circuit low input
The PCM monitors the input signal from the ECT sensor. If the voltage from the ECT sensor is less than 0.20
V for 2.0 s, the PCM determines that there is a malfunction in the ECT sensor circuit.
P0118 Engine coolant temperature (ECT) sensor circuit high input
The PCM monitors the input signal from the ECT sensor. If the voltage from the ECT sensor is more than 4.91
V for 1.0 s, the PCM determines that there is a malfunction in the ECT sensor circuit.
P0122 Accelerator pedal position (APP) sensor No.1 circuit low input
The PCM monitors the input signal from APP sensor No.1. If the voltage from APP sensor No.1 .is less than
0.29 V for 0.5 s when the APP sensor No.1 power supply voltage is normal, the PCM determines that there is
a malfunction in the APP sensor No.1 circuit.
P0123 Accelerator pedal position (APP) sensor No.1 circuit high input
The PCM monitors the input signal from APP sensor No.1. If the voltage from APP sensor No.1 is more than
P0182 Fuel temperature sensor circuit low input
The PCM monitors the input signal from the fuel temperature sensor. If the voltage from the fuel temperature
sensor is less than 0.2 V, the PCM determines that there is a malfunction in the fuel temperature sensor
circuit.
01-028-10
P0183 Fuel temperature sensor circuit high input
The PCM monitors the input signal from the fuel temperature sensor. If the voltage from the fuel temperature
sensor is more than 4.9 V, the PCM determines that there is a malfunction in the fuel temperature sensor
.\ circuit.
\
P0191 Fuel pressure sensor range/performance malfunction
The PCM monitors the fuel pressure in the common rail and input signal from the fuel pressure sensor while
the engine is running. If all of the following conditions is met, the PCM determines that there is malfunction in
the fuel pressure sensor range/performance malfunction.
The PCM calculates the difference between the actual fuel pressure and the target fuel pressure. If the
pressure difference is more than 5 MPa {51 kgf/cm 2 , 726 psi}.
The PCM monitors the input signal from the fuel pressure sensor. If the difference between the maximum
and minimum voltage of the fuel pressure sensor is less than 0.01 V.
P0192 Fuel pressure sensor circuit low input
The PCM monitors the input voltage from the fuel pressure sensor while the engine is running. If the input
voltage from the fuel pressure sensor is less than 0.2 V, the PCM determines that there is a malfunction in the
fuel pressure sensor circuit.
P0193 Fuel pressure sensor circuit high input
The PCM monitors the input voltage from the fuel pressure sensor while the engine is running. If the input
voltage from the fuel pressure sensor is more than 4.8 V, the PCM determines that there is a malfunction in
the fuel pressure sensor circuit.
P0201 Fuel injector No.1 circuit open/short
The PCM monitors each cylinder fuel injector control signal current while the engine is running. If the PCM
detects a control signal current of more or less than the preprogrammed criteria, the PCM determines that the
fuel injector at No.1 cylinder has an open or short circuit.
detects a control signal current of more or less than the preprogrammed criteria, the PCM determine that the
fuel injector at NO.3 cylinder has an open or short circuit. .
The PCM monitors the input signal from APP sensor No.2. If the voltage from APP sensor No.2 is less than
The PCM monitors the input signal from APP sensor No.2. If the voltage from APP sensor No.2 is more than
4.80 V for 0.5 s when the APP sensor no.2 power supply voltage is normal, the PCM determines that there is a
malfunction in the APP sensor No.2 circuit.
P0227 Idle switch circuit low input
The PCM monitors the input voltage from APP sensor No.1 when the idle switch is off. If the input voltage is
less than 0.86 V for 1.5 s, the PCM determines that the idle switch circuit has a malfunction.
P0228 Idle switch circuit high input
The PCM monitors the input voltage from APP sensor No.1 when the idle switch is on. If the input voltage is
more than 1.35 V for 1.5 s, the PCM determines that the idle switch circuit has a malfunction.
P0300 Random misfire detected
The PCM monitors the CKP sensor input signal interval time. The PCM calculates the deviation of the interval
time for each cylinder. If the deviation of the interval time exceeds the preprogrammed criteria, the PCM detects
a misfire in the corresponding cylinder. While the engine is running, the PCM counts the number of misfires and
calculates the misfire ratio for each crankshaft revolution. If the ratio exceeds the preprogrammed criteria, the
PCM determines that a misfire, which can affect emission performance, has occurred.
P0301, P0302, P0303, P0304 Cylinder No.1 No.2 No.3 No.4 misfire detection
The PCM monitors the CKP sensor input signal interval time. The PCM calculates the deviation of the interval
time for each cylinder. If the deviation of the interval time exceeds the preprogrammed criteria, the PCM detects
a misfire in the corresponding cylinder. While the engine is running, the PCM counts the number of misfires and
calculates the misfire ratio for each crankshaft revolution. If the ratio exceeds the preprogrammed criteria, the
PCM determines that a misfire, which can affect emission performance, has occurred.
01-028-11
P0335 Crankshaft position (CKP) sensor circuit malfunction
The PCM monitors the input signal from the CKP sensor while the engine is running. If the following conditions
are detected, the PCM determines that the CKP circuit has a malfunction.
- The PCM receives no pulse from the CKP sensor ( .
- The PCM receives an improper pulse number from the CKP sensor \ .
P0340 Camshaft position (CMP) sensor circuit malfunction
The PCM monitors the input signal from the CMP sensor while the engine is running. If the following conditions
are detected, the PCM determines that the CMP circuit has a malfunction.
- The PCM receives no pulse from the CMP sensor
- The PCM receives an improper pulse number from the CMP sensor
P0380 Glow plug relay circuit malfunction
The PCM monitors the glow plug relay control signal. If the following conditions are detected, the PCM
determines that the glow plug relay circuit has a malfunction.
- The PCM turns the glow plug relay off but the voltage remains low
- The PCM turns the glow plug relay on but the voltage remains high
- The PCM internal driver IC temperature is more than 150 C {320 F} when the glow plug relay is on
P0401 EGR flow insufficient detected
The PCM monitors the difference between the target air amount and intake air amount while the EGR system is
operating at EGR feedback control. If the difference between the target air amount and the intake air amount is
less than the threshold, the PCM determines that there is a malfunction in the EGR system.
P0402 EGR flow excessive detected
The PCM monitors the difference between the target air amount and intake air amount while the EGR system is
operating at EGR feedback control. If the difference between the target air amount and the intake air amount is
more than the threshold, the PCM determines that there is a malfunction in the EGR system.
P0403 EGR solenoid valve circuit malfunction
The PCM monitors the EGR solenoid valve control signal. If the following conditions are detected, the PCM
determines that the EGR solenoid valve circuit has a malfunction (open circuit).
- The PCM turns the EGR solenoid valve off but the voltage remains low
- The PCM internal driver IC temperature is more than 150 C {320 F} when the EGR solenoid valve is on
P0404 EGR control circuit range/performance
The PCM monitors the difference between target EGR valve lift and actual EGR valve lift under the
programmed condition.
If the difference is more or less than the programmed criteria the PCM determines that there is a malfunction in
the EGR control circuit.
P0405 EGR valve position sensor circuit low input
The PCM monitors the input voltage from the EGR valve position sensor while the engine is running. If the input
voltage is less than 0.1 V, the PCM determines that the EGR valve position sensor circuit has a malfunction.
P0406 EGR valve position sensor circuit high input
The PCM monitors the input voltage from the EGR valve position sensor while the engine is running. If the input
voltage is more than 4.9 V, the PCM determines that the EGR valve position sensor circuit has a malfunction.
P0489 EGR solenoid valve control circuit low input ,
The PCM monitors the EGR solenoid valve control signal. If the PCM turns the EGR solenoid valve off but the
voltage remains low, the PCM determines that EGR solenoid valve circuit has a malfunction (circuit short to
ground).
P0490 EGR solenoid valve control circuit high input
The PCM monitors the EGR solenoid valve control signal. If the PCM turns the EGR solenoid valve on but the
voltage remains high, the PCM determines that EGR solenoid valve circuit has a malfunction (circuit short to
power supply).
P0500 VSS circuit malfunction
The PCM monitors the input signal from the instrument cluster during set conditions. If the input signal is less
than 0 km/h {O mph} for 25 s, the PCM determines that there is a VSS circuit malfunction.
P0562 Battery voltage low input
The PCM monitors the battery voltage. If the battery voltage is less than 8 V, the PCM determines that there is
a malfunction in the battery and the battery signal system.
P0563 Battery voltage high input
The PCM monitors the battery voltage. If the battery voltage is more than 16 V, the PCM determines that there
is a malfunction in the battery charging system.
P0602 PCM programming error
No configuration data in the PCM
P0606 PCM malfunction
PCM internal malfunction.
P0607 PCM performance problem
PCM internal malfunction.
P061 0 PCM vehicle options error
PCM data configuration error
01-028-12
P0627 Fuel metering valve control circuit open
The PCM monitors the fuel metering valve driver IC temperature in the PCM and the control voltage while the
engine is running. If either of the following conditions is met, the PCM determines that there is a malfunction in
the fuel metering valve range/performance.
The PCM monitors the fuel metering valve driver IC temperature in the PCM. If the fuel metering valve
driver IC temperature is more than 150 C {320 F} during the fuel metering valve operation, the PCM
determines that the fuel metering valve has a malfunction
The PCM monitors the fuel metering valve control voltage at the PCM terminals. If fuel metering valve
control voltage is less than 5 V when fuel metering valve is not operating, the PCM determines that the fuel
metering valve has a malfunction (open circuit)
P0628 Fuel metering valve control circuit low input
The PCM monitors the fuel metering valve circuit voltage while the engine is running. If the PCM detects that
the circuit voltage is low when the fuel metering valve is off, the PCM determines that there is a malfunction in
the fuel metering valve circuit (circuit short to ground).
P0629 Fuel metering valve control circuit high input
The PCM monitors the fuel metering valve circuit voltage while the engine is running. If the peM detects that
the circuit voltage is high when the fuel metering valve is on, the PCM determines that there is a malfunction in
the fuel metering valve circuit (circuit short to power supply).
P0642 Fuel pressure sensor and boost sensor 5 V circuit low input
The PCM monitors the fuel pressure sensor and the boost sensor 5 V circuit. If the fuel pressure sensor and
boost sensor power voltage is lower than 4.9 V, the peM determines that there is a fuel pressure sensor and
boost sensor 5 V circuit malfunction.
P0643 Fuel pressure sensor and boost sensor 5 V circuit high input
The PCM monitors the fuel pressure sensor and boost sensor 5 V circuit. If the fuel pressure sensor and boost
sensor power voltage is higher than 4.9 V, the PCM determines that there is a fuel pressure sensor and boost
sensor 5 V circuit malfunction.
P0652 CMP sensor and APP sensor 5 V circuit low input
The PCM monitors the CMP sensor and APP sensor 5 V circuit. If the CMP sensor and APP sensor power
voltage is lower than 4.9 V, the PCM determines that there is a CMP sensor and APP sensor 5 V circuit
malfunction.
P0653 CMP sensor and APP sensor 5 V circuit high input
The PCM monitors the CMP sensor and APP sensor 5 V circuit. If the CMP sensor and APP sensor power
voltage is higher than 5.1 V, the PCM determines that there is a CMP sensor and APP sensor 5 V circuit
malfunction.
P0660 Intake shutter solenoid valve (half) control circuit open
The PCM monitors the intake shutter solenoid valve (half) control signal. If the following conditions are
detected, the PCM determines that the intake shutter solenoid valve (half) control circuit has a malfunction.
The PCM turns the intake shutter solenoid valve (half) off, but the intake shutter solenoid valve (half) control
voltage is less than 5 V for 2 s (open circuit)
- The PCM internal driver IC temperature is more than 150 C {320 F} when the intake shutter solenoid
valve (half) is on
P0661 Intake shutter solenoid valve (half) control circuit low input
The peM monitors the intake shutter solenoid valve (half) control signal at peM terminal 152. If the peM turns
the intake shutter solenoid valve (half) off but the voltage at PCM terminal 152 remains low, the peM
determines that intake shutter solenoid valve (half) circuit has a malfunction (circuit short to ground).
P0662 Intake shutter solenoid valve (half) control circuit high input
The PCM monitors the intake shutter solenoid valve (half) control signal at peM terminal 152. If the peM turns
the intake shutter solenoid valve (half) on but the voltage at PCM terminal 152 remains high, the PCM
determines that the intake shutter solenoid valve (half) circuit has a malfunction (circuit short to power supply).
P0663 Intake shutter solenoid valve (full) control circuit open
The PCM monitors the intake shutter solenoid valve (full) control signal. If the following conditions are detected,
the PCM determines that the intake shutter solenoid valve (full) control circuit has a malfunction.
The peM turns the intake shutter solenoid valve (full) off, but the intake shutter solenoid valve (full) control
voltage is less than 5 V for 2 s (open circuit)
- The peM internal driver IC temperature is more than 150 C {320 F} when the intake shutter solenoid
valve (full) is on
P0664 Intake shutter solenoid valve (full) control circuit low input
The PCM monitors the intake shutter solenoid valve (full) control signal at peM terminal 155. If the PCM turns
the intake shutter solenoid valve (full) off, but the voltage at PCM terminal 155 remains low, the peM
determines that intake shutter solenoid valve (full) circuit has a malfunction (circuit short to ground).
P0665 Intake shutter solenoid valve (full) control circuit high input
The PCM monitors the intake shutter solenoid valve (full) control Signal at PCM terminal 155. If the PCM turns
the intake shutter solenoid valve (full) on, but the voltage at PCM terminal 155 remains high, the PCM
determines that the intake shutter solenoid valve (full) circuit has a malfunction (circuit short to power supply).
01-028-13
ON-BOARD DIAGNOSTIC [WL-C, WE-C] ,
P0685 Main relay control circuit open
The PCM monitors the power supply to the PCM. If the power supply is shut down several times when the
engine switch is turned to the ON position, the PCM determines that there is a power circuit malfunction (open
circuit).
P0698 EGR valve position sensor 5 V circuit low input
The PCM monitors the EGR position sensor 5 V circuit. If the EGR position sensor power voltage is lower than
4.9 V, the PCM determines that there is a EGR position sensor 5 V circuit malfunction.
P0699 EGR valve position sensor 5 V circuit high input
The PCM monitors the EGR position sensor 5 V circuit. If the EGR position sensor power voltage is higher
than 5.1 V, the PCM determines that there is a EGR position sensor 5 V circuit malfunction.
P1196 Key off voltage high input
The PCM monitors whether the main relay opens after 2 s when the engine switch is turned to the off position.
If the main relay does not open after 2 s, the PCM determines that there is malfunction in the main relay circuit.
P1259 IMMOBILIZER to PCM signal error
The PCM does not complete target 10 transfer.
P1260 Theft detected Vehicle immobilizer
Immobilizer system malfunction
P1391 Glow plug control circuit low input
The PCM monitors the output signal to the glow plug relay when the glow plug relay is on. If the glow plug relay
voltage is less than 2 V for 1 s when the glow plug relay is operating, The PCM determines that there is a
malfunction in the glow plug relay circuit.
P1392 Glow plug control circuit high input
The PCM monitors the output signal to the glow plug relay when the glow plug relay is off. If the glow plug relay
voltage is more than 2 V for 1 s when the glow plug relay is off, The PCM determines that there is a
malfunction in the glow plug relay control circuit.
P1528 Exhaust shutter solenoid valve circuit problem
The PCM monitors the input voltages from the exhaust shutter solenoid valve. If the voltage remains low or
high, the PCM determines that the exhaust shutter solenoid valve circuit has malfunction.
P1602 Immobilizer/PCM communication error
PCM internal malfunction
P160310 Number Unregistered
P1604 Code word unregistered
P1621 Immobilizer code word does not match
Cord word stored in immobilizer system and PCM does not to match.
10 number stored in immobilizer system and PCM does not to match.
P1622 Immobilizer 10 does not match
P1623 Immobilizer code wordllO number write failure
P1624 Anti-theft system
P1675 Injection quantity adjustment value writing error
The fuel injector compensation data configuration has not been completed.
P1676 Injection quantity adjustment value checksum error
The fuel injector compensation data check sum error.
P2008 Variable swirl control (VSC) solenoid valve control circuit open
The PCM monitors the VSC solenoid valve control signal. If the following conditions are detected, the PCM
determines that the VSC solenoid valve control circuit has a malfunction.
- The PCM turns the VSC solenoid valve off, but the VSC solenoid valve control voltage is less than 5 V for
2 s (open circuit)
- The PCM internal driver IC temperature is more than 150 C {320 F} when the VSC solenoid valve is on
P2009 Variable swirl control (VSC) solenoid valve circuit low input
The PCM monitors the output signal to the VSC solenoid valve. If the voltage of the VSC solenoid valve is low
even if the VSC solenoid valve is off, the PCM determines that there is a malfunction in the VSC solenoid valve
control circuit. -
P2010 Variable swirl control (VSC) solenoid valve circuit high input .. )
The PCM monitors the output signal to the VSC solenoid valve. If the voltage of the VSC solenoid valve is high
even if the VSC solenoid valve is on, the PCM determines that there is a malfunction in the VSC solenoid valve
control system.
01-028-14
P2135 Accelerator pedal position (APP) sensor No.1/No.2 voltage correlation problem
The PCM monitors the input signals from accelerator pedal position sensor No.1 and accelerator pedal position
sensor NO.2. If the difference between accelerator pedal position sensor No.1 and accelerator pedal position
" . '. sensor No.2 is more than 0.9 V for 0.5 s, the PCM determines that there is a malfunction in the accelerator
pedal position sensor characteristic.
P2136 Accelerator pedal position (APP) sensor No.lIidle switch voltage correlation problem
The PCM compares the input voltage from APP sensor No.1 with the input voltage from the idle switch when
the accelerator pedal is released (idle switch is on). If the difference is more than 1.35 V for 0.5 s, the PCM
determines that there is an APP sensor No.1/idle switch angle correlation problem.
P2143 EGR control solenoid valve control circuit open
The PCM monitors the EGR control solenoid valve control signal. If the following conditions are detected, the
PCM determines that the EGR control solenoid valve circuit has a malfunction.
- The PCM turns the EGR control solenoid valve off but the voltage remains low (open circuit).
- The PCM internal driver IC temperature is more than 150 C {320 F} when the EGR control solenoid valve
is on.
P2144 EGR control solenoid valve control circuit low input
The PCM monitors the EGR control solenoid valve control signal. If the PCM turns the EGR control solenoid
valve off but the voltage remains low, the PCM determines that the EGR control solenoid valve circuit has a
malfunction (circuit short to ground).
P2145 EGR control solenoid valve control circuit high input
The PCM monitors the EGR control solenoid valve control signal. If the PCM turns the EGR control solenoid
valve on but the voltage still remains high, the PCM determines that the EGR control solenoid valve circuit has
a malfunction (circuit short to power supply).
P2146 Fuel injector No.1 and No.4 power supply circuit malfunction
The PCM monitors the fuel injector No.1 and No.4 power supply voltage when the engine is running. If the
following conditions are detected 5 times, the PCM determines that the fuel injector No.1 and No.4 power
supply circuit has a malfunction.
- Fuel injector No.1 and No.4 power supply voltage is less than 43 V
- Fuel injector No.1 and No.4 power supply voltage is 53 V or above
P2147 Fuel injector No.1 and No.4 power supply circuit low input
The PCM monitors the fuel injector No.1 and No.4 power supply current when the engine is running. If the
power supply current is 25 A or above 3 times while other fuel injector power supply current is 25 A or above,
the PCM determines that the fuel injector No.1 and No.4 power supply current is too high.
P2148 Fuel injector No.1 and No.4 power supply circuit high input
The PCM monitors the fuel injector No.1 and No.4 power supply current when the engine is running. If the
power supply current is 50 A or above 3 times, the PCM determines that the fuel injector No.1 and No.4 power
supply current is too high.
P2149 Fuel injector No.2 and No.3 power supply circuit malfunction
The PCM monitors the fuel injector No.2 and NO.3 power supply voltage when the engine is running. If the
following conditions are detected 5 times, the PCM determines that the fuel injector No.2 and NO.3 power
- Fuel injector No.2 and NO.3 power supply voltage is less than 43 V
P2150 Fuel injector No.2 and No;3 power supply circuit low input
The PCM monitors the fuel injector No.2 and NO.3 power supply current when the engine is running. If the
power supply current is 25 A or above 3 times while other fuel injector power supply current is 25 A or above,
the PCM determines that the fuel injector No.2 and No.3 power supply current is too high.
P2151 Fuel injector No.2 and No.3 power supply circuit high input
The PCM monitors the fuel injector No.2 and NO.3 power supply current when the engine is running. If the
power supply current is 50 A or above 3 times, the PCM determines that the fuel injector No.2 and NO.3 power
supply current is too high.
P2227 BARO sensor circuit range/performance malfunction
The PCM monitors the input signal from the barometric pressure sensor. If the difference between the
barometric pressure input from the barometric pressure sensor and the boost pressure is more than 11 kPa
{0.11 bar, 1.6 psi}, the PCM determines that there is a malfunction in the barometric pressure sensor.
P2228 BARO sensor circuit low input
The PCM monitors the input signal for the barometric pressure. If the voltage from the barometric pressure
sensor is less than 2.2 V for 1 s, the PCM determines that there is a malfunction in the barometric pressure
sensor signal system.
P2229 BARO sensor circuit high input
The PCM monitors the input signal for the barometric pressure. If the voltage from the barometric pressure
sensor is more than 4.8 V for 1 s, the PCM determines that there is a malfunction in the barometric pressure
sensor signal system.
01-028-14a
P2263 Air charging pressure performance malfunction

The peM monitors the air charging pressure. If the air charging pressure is not within the specification for the
peM control target, the peM determines that there is a malfunction in the air charging system.
P2530 PCM (engine. switch circuit) malfunction
peM internal malfunction.
PID/DATA MONITOR AND RECORD [WL-C, WE-C]

dcf010200000l17
The PID/DATA monitor items are shown below.
PID/DATA 'T'onitor item table
Monitor item Definition Unit/Condition PCM terminal
AAT Ambient temperature C -
AC_REQ AlC request signal Off/On 239
ACCS Air conditioning compressor cycling switch Off/On 128
APP Accelerator pedal position % 209,222
%
APP1 Accelerator pedal position sensor No.1 222
V
%
APP2 Accelerator pedal position sensor No.2 209
V
ARPMDES Target engine speed rpm -
,
Pa
BARO Barometric pressure -
V
BOO Brake switch Off/On 238
CPP Clutch pedal position switch Off/On 228
DTCCNT DTC count (includes those needing no action) No unit -
C
ECT Engine coolant temperature 167
V
EGRV2 EGR solenoid valve (vent) Off/On 177
A
FIP _FL Supply pump flow control 179 i
%
FIP_SCV Fuel metering valve A 179
FLT Fuel temperature C 115
FRP Fuel pressure sensor Pa 140
GP _LMP Glow indicator light Off/On 233
GPC Glow plug relay Off/On 182
IASV Intake shutter solenoid valve (half) Off/On 152
IASV2 Intake shutter solenoid valve (full) Off/On 155
C
IAT Intake air temperature (IAT sensor No.1) 141
V
INGEAR Load/no load condition Off/On 240
IVS Idle switch Off Idle/Idle 161
LOAD Engine load % -
g/s
MAF Mass airflow amount 190
V
Pa
MAP Boost sensor 189
V
MIL Malfunction indicator lamp Off/On 256
MIL_DIS The distance travelled since the MIL was activated km/h -
RPM Engine speed rpm 193
SEGRP DSD Desired EGR valve position % -
SELTESTDTC Diagnostic trouble codes No unit -
VBCV VBC solenoid valve % 178
VPWR Module supply voltage V 201,203,205
VSS Vehicle speed km/h 184
WARM SW Exhaust heating switch Off/On -
01-028-15
SIMULATION TEST [WL-C, WE-C]
dcf01020000Ot18
The simulation items are shown below.

C,~imulation item table
: Applicable
-: Not applicable
Test condition
Item Applicable component Unit/condition PCM terminal
KOEO KOER
ACCS Air conditioning compressor cycling switch Off/On - 128
EGRV2 EGR solenoid valve (vent) Off/On - 177
GP _LMP Glow indicator light Off/On - 233
GPC Glow plug relay Off/On - 182
IASV Intake shutter solenoid valve (half) Off/On - 152
IASV2 Intake shutter solenoid valve (full) Off/On - 155
INJ_1 Fuel injector No.1 Off - 125, 174
INJ_3 Fuel injector No.3 Off - 101,173
SEGRP EGR valve position sensor 0/0 - 116
VBCV VBC solenoid valve 0/0 - 178
WARM_SOL Exhaust shutter solenoid valve Off/On - -
01-028-16
KOEO/KOER SELF-TEST[WL-C, WE-C]

id01 02c41 00400
: Applicable
- : Not applicable
OTC Condition KOEO KOER
POO16 CKP-CMP correlation -
POO45 Variable boost control (VBC) solenoid valve control circuit open
Variable boost control (VBC) solenoid valve circuit range/performance
POO46
malfunction
POO47 Variable boost control (VBC) solenoid valve control circuit low input
POO48 Variable boost control (VBC) solenoid valve control circuit high input
POO88 Fuel pressure system too high - -
POO93 Fuel system leak detection - -
POO97 Intake air temperature (IAT) sensor No.2 circuit low input
POO98 Intake air temperature (IAT) sensor No.2 circuit high input
P0101 Mass airflow (MAF) sensor range/performance malfunction - -
P0102 Mass airflow (MAF) sensor circuit low input -
P0103 Mass airflow (MAF) sensor circuit high input -
P0106 Boost sensor range/performance malfunction - -
P0107 Boost sensor circuit low input
P0108 Boost sensor circuit high input
P0111 Intake air temperature (IAT) sensor No.1 range/performance malfunction - -
P0113 Intake air temperature (IAT) sensor No.1 circuit high input
P0116 Engine coolant temperature (ECT) sensor range/performance malfunction - -
P0117 Engine coolant temperature (ECT) sensor circuit low input
P0118 Engine coolant temperature (ECT) sensor circuit high input
P0182 Fuel temperature sensor circuit low input
P0183 Fuel temperature sensor circuit high input
P0191 Fuel pressure sensor range/performance malfunction -
P0192 Fuel pressure sensor circuit low input
P0193 Fuel pressure sensor circuit high input
P0201 Fuel injector No.1 circuit open/short -
P0227 Idle switch circuit low input - -
P0228 Idle switch circuit high input - -
P0300 Random misfire detected -
P0301 Cylinder No.1 misfire detection -
P0335 Crankshaft position (CKP) sensor circuit malfunction -
P0340 Camshaft position (CMP) sensor circuit malfunction -
P0380 Glow plug relay circuit malfunction -
P0401 EGR flow insufficient detected - -
( ....
01-028-17
DTC Co ndition KOEO KOER

P0402 EGR flow excessive detected - -
P0403 EGR solenoid valve circuit malfunction
P0404 EGR control circuit range/performance -
P0405 EGRvalve position sensor circuit low input
,
P0406 EGR valve position sensor circuit high input
P0489 EGR solenoid valve control circuit low input -
P0490 EGR solenoid valve control circuit high input -
P0500 VSS circuit malfunction - -
P0562 Battery voltage low input
P0563 Battery voltage high input
P0602 PCM programming error
P0606 PCM malfunction
P0607 PCM performance problem
P0610 PCM vehicle options error
P0627 Fuel metering valve control circuit open -
P0628 Fuel metering valve control circuit low input -
P0629 Fuel metering valve control circuit high input -
P0642 Fuel pressure sensor and boost sensor 5 V circuit low input
P0643 Fuel pressure sensor and boost sensor 5 V circuit high input
P0652 CMP sensor and APP sensor 5 V circuit low input
P0653 CMP sensor and APP sensor 5 V circuit high input
P0660 Intake shutter solenoid valve (half) control circuit open -
P0661 Intake shutter solenoid valve (half) control circuit low input -
P0662 Intake shutter solenoid valve (half) control circuit high input -
P0663 Intake shutter solenoid valve (full) control circuit open -
P0664 Intake shutter solenoid valve (full) control circuit low input -
P0665 Intake shutter solenoid valve (full) control circuit high input -
P0685 Main relay control circuit open - -
P0698 EGR valve position sensor 5 V circuit low input
P0699 EGR valve position sensor 5 V circuit high input
P1196 Key off voltage high input - -
P1259 IMMOBILIZER to PCM signal error -
P1260 Theft detected Vehicle immobilizer -
P1391 Glow plug control circuit low input -
P1392 Glow plug control circuit high input -
P1528 Exhaust shutter solenoid valve circuit problem -
P1602 Immobilizer/PCM communication error -
P1603 10 Number Unregistered -
P1604 Code word unregistered -
P1621 Immobilizer code word does not match -
P1622 Immobilizer 10 does not match -
P1623 Immobilizer code word/IO number write failure -
P1624 Anti-theft system -
P1675 Injection quantity adjustment value writing error -
P1676 Injection quantity adjustment value checksum error -
P2008 Variable swirl control (VSC) solenoid valve control circuit open -
P2009 Variable swirl control (VSC) solenoid valve circuit low input -
P2010 Variable swirl control (VSC) solenoid valve circuit high input -
P2135 Accelerator pedal position (APP) sensor No.1/No.2 voltage correlation problem
Accelerator pedal position (APP) sensor No.1 /idle switch voltage correlation
P2136
problem
P2143 EGR control solenoid valve control circuit open -
P2144 EGR control solenoid valve control circuit low input
P2145 EGR control solenoid valve control circuit high input
P2146 Fuel injector No.1 and No.4 power supply circuit malfunction -
01-028-18
OTC Condition KOEO KOER

P2147 Fuel injector No.1 and No.4 power supply circuit low input -
P2148 Fuel injector No.1 and No.4 power supply circuit high input -
P2149 Fuel injector No.2 and No.3 power supply circuit malfunction -
P2150 Fuel injector No.2 and No.3 power supply circuit low input -
P2151 Fuel injector No.2 and No.3 power supply circuit high input -
P2227 BARO sensor circuit range/performance malfunction - -
P2228 BARO sensor circuit low input
P2229 BARO sensor circuit high input
P2263 Air charging pressure performance malfunction - -
P2530 PCM (engine switch circuit) malfunction -
01-02C-19
MECHANICAL [WL-C, WE-C]
01-108 MECHANICAL [WL-C, WE-C]

ENGINE STRUCTURAL VIEW CONNECTING ROD,
[WL-C, WE-C] .•. ,...•........•.... 01-10B-1 CONNECTING ROD BEARING
CYLINDER HEAD COVER CONSTRUCTION [WL-C, WE-C] ....• 01-10B-5
CONSTRUCTION [WL-C, WE-C] ..... 01-10B-1 DRIVE BELT CONSTRUCTION
CYLINDER HEAD CONSTRUCTION [WL-C, WE-C] ...•.•....•••....•... 01-10B-5
[WL-C, WE-C] .•........•......•.. 01-10B-2 VALVE MECHANISM STRUCTURAL
CYLINDER HEAD GASKET VIEW [WL-C, WE-C] ..•...•.....•... 01-10B-6
CONSTRUCTION [WL-C, WE-C] .••.. 01-10B-2 TIMING GEAR CONSTRUCTION
CYLINDER BLOCK [WL-C, WE-C] •..•..........•..... 01-1 OB-6
CONSTRUCTION [WL-C, WE-C] .•... 01-10B-2 CAMSHAFT CONSTRUCTION
CRANKSHAFT, MAIN BEARING [WL-C, WE-C] •••....•.....••..... 01-1 OB-8
CONSTRUCTION [WL-C, WE-C] ..... 01-10B-3 AUTO TENSIONER CONSTRUCTION
CRANKSHAFT PULLEY [WL-C, WE-C] .•.......•...•...... 01-10B-8
CONSTRUCTION [WL-C, WE-C] ..... 01-10B-4 VALVE, ROCKER ARM
PISTON CONSTRUCTION CONSTRUCTION [WL-C, WE-C] ...... 01-10B-9
[WL-C, WE-C] ..........•......•.. 01-10B-4 ENGINE MOUNT STRUCTURAL
VIEW [WL-C, WE-C] ................ 01-10B-9
ENGINE STRUCTURAL VIEW [WL-C, WE-C]

dcf011002000t02
DGB110BTB001
CYLINDER HEAD COVER CONSTRUCTION [WL-C, WE-C]

dcf011 01 022Ot02
• The cylinder head cover is made of aluminum alloy.
• The cylinder head cover is made of aluminum alloy with a baffle plate on its lower side for blow-by gas
separation.
01-108-1
CYLINDER HEAD CONSTRUCTION [WL-C, WE-C]
dcf011 01 010Ot02
• A lightweight aluminum alloy cylinder head with good thermal conductivity has been adopted.
• A plastic region bolt has been adopted as a cylinder head bolt providing constant high axial force (tightening
force).
• Due to the adoption of 4 valves, the opening area has been increased and the charging efficiency improved.
• The smooth curved intake port reduces intake resistance.
DBG110BTB801
CYLINDER HEAD GASKET CONSTRUCTION [WL-C, WE-C]

dcf011010271to2
• A steel-laminated gasket has been adopted for the cylinder head gasket.
CYLINDER BLOCK CONSTRUCTION [WL-C, WE-C]

dcf011 01 030Ot02
• A special cast iron liner-less type cylinder block has been adopted to provide a thin-walled cylinder block. In
addition, a curve-shaped, deep-skirt cylinder block has been adopted to heighten the cylinder block rigidity.
• The engine coolant passage has been equipped by cross-drilling in the bore, improving the cooling
performance and reducing oil consumption.
SECTION A-A
CROSS DRILL HOLE
DGB110BTB002
01-108-2
CRANKSHAFT, MAIN BEARING CONSTRUCTION [WL-C, WE-C]
dcf011 011301 t02
Structure
• A five axle-hole, 8 counter weight steel crankshaft has been adopted.
• An oil line for supplying oil to each journal is provided in the crankshaft. Crank pins and fillets on both sides of
the journal are rolled to bear heavy loads. .
• Upper and lower main bearings are made of aluminum alloy and thrust bearings are used at the No.3 journal.
The upper main bearing has oil grooves and oil holes.
LOWER THRUST BEARING
FILLET ROLL AREA
OIL PASSAGE
DBG110BTB004
01-108-3
CRANKSHAFT PULLEY CONSTRUCTION [WL-C, WE-C)
dcfD11011371t02
Structure
• A torsional damper pulley is used for the crankshaft pulley to reduce torsional vibration noise.
• The pulley installation area has a pulley cover for reduction of engine noise.
TORSIONAL DAM PAR
PULLEY COVER
DBG110BTB802
PISTON CONSTRUCTION [WL-C, WE-C)

dcf011 011 01 0102
Structure
• In accordance with the adoption of the common rail injection system, the piston head shape (combustion
chamber) has been changed.
• A reduction in friction has been achieved by the coating of the skirt area together with a compression rating
setting of 18.0.
• To realize high combustion efficiency, the diffusion area of the hotspot at combustion has been expanded by : ..
the change in the shape of the combustion chamber and the spray pattern of fuel injectors. Exhaust emission
and combustion noise have been reduced through smooth and uniform combustion.
COMBUSTION CHAMBER
COATING
DBG110BTB803
01-108-4
CONNECTING ROD, CONNECTING ROD BEARING CONSTRUCTION [WL-C, WE-C]
dcf011011211t02
Structure
• Connecting rods are made of forget manganese steel.
• Dowel pins are used to position the rod cap to the connecting rod.
• Connecting rod caps are secured with plastic region bolts.
• The connecting rod bearing is mode of aluminum alloy.
BUSH
, , " ' - _ - - - CONNECTING ROD
CONNECTING ROD UPPER BEARING
CONNECTING ROD CAP
uv-------"CONNECTING ROD CAP BOLT
DBG110BTB804
DRIVE BELT CONSTRUCTION [WL-C, WE-C]

dcf01101580Dt01
Structure
• A V-belt has been adopted which consists of three belts including generator and water pump operation belts
(two belts), and an AIC compressor operation belt.
GENERATOR
PULLEY
DRAIVEBELT
(V-BELT)
IDLER
WATER PUMP
PULLEY AlC COMPRESSOR
PULLEY
CRANKSHAFT
PULLEY
DGB110BTB003
01-108-5
VALVE MECHANISM STRUCTURAL VIEW [WL-C, WE-C]
dcf011 012111 101
RARM
TIMING BELT
BALANCE SHAFT
DBG110BTB805
TIMING GEAR CONSTRUCTION [WL-C, WE-C]

dcf011012111to2
Supply Pump Gear
• The gears are helical. Supply pump gear is combined with a scissors gear.
• The scissors gear, through the force of the scissors gear spring, prevents the teeth of the supply pump gear
from moving back and forth (backlash) between the teeth of the No.2 idler gear, with which the supply pump
gear is meshed, and thus reduces gear noise.
• When removing the supply pump gear, fix the scissors gear to the supply pump gear using a lock bolt (M6 x
1.0, length under the bolt head is approximately 10 mm {0.63 in} to prevent the scissors gear from rotating
under the spring force.
01-108-6
MECHANICAL [WL-C, WE-C)
SUPPLY PUMP GEAR (NO.2 IDLER GEAR
SCISSORS GEAR (DOTTED LINE)
SUPPLY PUMP GEAR
SCISSORS GEAR SPRING
SCISSORS GEAR
BALL BEARING
FRICTION GEAR HELICAL GEAR
NO.3 IDLE GEAR
FRICTION GEAR
DBG110BTB806
01-108-7
CAMSHAFT CONSTRUCTION [WL-C, WE-C)
dcf011 012111 103
• The camshaft is made of cast iron alloy.
• A hollow type,camshaft with five bearings has been adopted. In addition, the hollow area is provided as the oil
passage.
• The camshaft No. 1 journal has a hexagonal shaped surface around the rear of the shaft to prevent rotation
during servicing.
• Thrust force is received at the front of the No. 1 journal.
HOLLOW (OIL PASSAGE)
THRUST FORCE RECEIVING AREA
EXH
INT
HEXAGONAL SHAPED SURFACE

HOLLOW (OIL PASSAGE)
DBG110BTBR01
AUTO TENSIONER CONSTRUCTION [WL-C, WE-C)

dcf011 012111 104
• A hydraulic timing belt auto tensioner has been adopted for timing belt adjustment so that the timing belt
tension is maintained constantly.
PLUNGER
BALL
c::t-t--+--OIL
PLUNGER SPRING
DBG110BTBRR2
01-108-8
VALVE, ROCKER ARM CONSTRUCTION [WL-C, WE-C]
dcf011012111t05
• The valves are operated by rocker arms.
• Valve clearance is adjusted by the adjust screw and nut of the rocker arm.
CAMSHAFT
VALVE STEM
DBG110BTB807
ENGINE MOUNT STRUCTURAL VIEW [WL-C, WE-C]

dcf01103900Ot02
4x4
DBG110BTB809
01-108-9
LUBRICATION [WL-C, WE-C]
01-11B LUBRICATION [WL-C, WE-C]

LUBRICATION SYSTEM OUTLINE OIL COOLER, OIL FILTER BODY
[WL-C, WE-C] .•...•.......•....•. 01-11B-1 CONSTRUCTION [WL-C, WE-C] ....•. 01-11B-4
LUBRICATION SYSTEM STRUCTURAL OIL PAN CONSTRUCTION
VIEW [WL-C, WE-C] .....••.•...... 01-11B-2 [WL-C, WE-C] .•..•.....•...... ; ... 01-11 B-4
LUBRICATION SYSTEM OIL STRAINER CONSTRUCTION
. FLOW DIAGRAM [WL-C, WE-C] .•..• 01-11B-3 [WL-C, WE-C} ......••...........' •• 01-11 B-5
OIL FILTER CONSTRUCTION OIL PUMP CONSTRUCTION
[WL-C, WE-C] .....•.•..•......•.. 01-11B-3 [WL-C, WE-C] .•.....•............ 01-11B-5
OIL JET VALVE CONSTRUCTIONI
OPERATION [WL-C, WE-C] .....••... 01-11 B-6
LUBRICATION SYSTEM OUTLINE [WL-C, WE-C]

Features
• Gear type oil pump adopted
Improved lubricity • Oil jet valves adopted
• Water-cooled type oil cooler adopted
Reduced weight • Plastic oil strainer adopted
Reduced engine noise • Oil pan baffle plate adopted
01-118-1
LUBRICATION SYSTEM STRUCTURAL VIEW [WL-C, WE-C]
dcf011100000105
OIL JET VALVE
OIL COOLER
~ O-RING
All:J~«A
--A
II .,../
OILPUMP j O-RING
GASKET ® OIL COOLER AND OIL OIL FILTER
FILTER BODY
OIL OUTLET PIPE
COMPONENT
AA
r;:-J----O-RING
OIL STRAINER ~
A L_
'7 OIL PAN
- :} ---~OIL PAN DRAIN PLUG

GASKET
DCG111 ZTB008
01-11 B-2
LUBRICATION SYSTEM FLOW DIAGRAM [WL-C, WE-C]
dcf01110000Ot06
1 . . . . . - - - - - - - - - - - - - .. 1
CAMSHAFT, ROCKER ARM
1 1
~+----------------------------~----~
OIL PRESSURE SWITCH

r8J ORIFICE VACUUM PUMP
~~r----------------r~f~~--+-~
OIL FILTER BODY~
I"---
~: BALANCESHAFT :~-~I'b~h 1
I L..J "-1\1...--4-1-~-----------'
I---I-r--""T"'""+--L..--+!:: MAIN BEARING
+ .:TURBOCHARGER I
I CRANKSHAFT I I PISTON I ) I
'- -----: I CONN~TING I I t I TIMING GEAR
OIL t ! ROD BEARING OIL JET VALVE

FILTER ~, ,
'---_ _--'/<IIf-L-Il----+-~::.-I1 OIL PUMP
I I ...
T
,,
,
. ,, ,,
, ,,
- - - - . OIL PASSAGE
, , , ,
--. OIL RELIEF PASSAGE e;z .. OIL PAN
- . OIL BYPASS PASSAGE

OIL STRAINER
DCG111 ZTB006
OIL FILTER CONSTRUCTION [WL-C, WE-C]

dcf01111430Ot02
• A full-flow paper element type oil filter has been adopted.
• The oil filter is installed on the oil filter body. (Left surface (vehicle left) of the cylinder block)
HEIGHT
OUTER
DIAMETER
DCG111ZTB001
Oil filter specification

Item Specification (mm {in})
Outer diameter 73.7 {2.90}
Height 100 {3.94}
01-118-3
OIL COOLER, OIL FILTER BODY CONSTRUCTION [WL-C, WE-C]
dcf011114700t02
• A water-cooled, 5-layered type oil cooler has been adopted to reduce engine oil degradation.
• The oil cooler, oil cooler bypass valve, and oil pressure control valve are built into the oil filter body.
..
( '.
OIL PRESSURE CONTROL

VALVE COMPONENT
OIL FILTER BODY ~

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

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

dcf01111004Ot02
• A steel oil pan has been adopted.

• A silicon sealant with excellent sealing qualities has been adopted. Also, sealing slots have been adopted on
the oil pan attachment side to improve sealing performance.
• An oil baffle plate has been installed inside the oil pan to bifurcate the oil pan bottom. Due to this, the vibrations
at the oil surface and in the oil pan have been reduced for improved engine noise suppression.
EXTERNAL VIEW
DCG111ZTB010
,.;
01-118-4
OIL STRAINER CONSTRUCTION [WL-C, WE-C]
dcf01111424ot02
• A plastic oil strainer with a resin filter in the middle of the strainer has been adopted for weight reduction.
EXTERNAL VIEW A-A SECTIONAL VIEW
RESIN FILTER
OIL STRAINER
OIL STRAINER
RESIN FILTER
OIL SUPPLY INLET
OIL PUMP CONSTRUCTION [WL-C, WE-C]

dcf011114100to2
• A gear type oil pump with superior heat resistance and noise reduction has been adopted, ensuring stable
discharge performance.
• The oil pump consists of the oil pump body, oil pump drive gear, driving gear, driven gear, relief valve, and oil
pump cover.
• The oil pump is driven by the crankshaft through the timing gear and oil pump drive gear.
• The relief valve is built into the oil pump body.
OIL PUMP DRIVE GEAR

DRIVING GEAR
OIL PUMP BODY
DCG111 ZTB005
Oil pump specification

Item Engine speed [rpm] Specification (kPa {kgf/cm 2 , psi})
Oil discharge pressure (reference value) At idling 100-330 {1.02-3.36, 14.5-47.7}
[after warm up] 2,500 410-570 {4.19-5.81, 59.6-82.6}
Relief valve opening pressure (reference value) 580-700 {5.9-7.1, 84.1-101.5}
01-118-5
OIL JET VALVE CONSTRUCTION/OPERATION [WL-C, WE-C)
dcf01111073ot02
Construction
• The oil jet valves are installed in the cylinder block. The oil jet valve nozzles are installed pointed toward the
back surface of each piston.
• The oil jet valves are designed to maintain optimum oil pressure in the engine by controlling the oil injection
according to the oil pressure applied to the check ball in the oil jet valves.
o o o CYLINDER BLOCK
MAIN GALLERY
TO BACK SURFACE
OF PISTON ENGINE OIL
I I 0 o o NOZZLE OIL JET VALVE

7
CYLINDER BLOCK
DCG111ZTB003
Operation
• Oil pressure applied to the check-ball in the oil jet valve opens and closes the oil passage-way to the nozzle
and controls oil injection starting and stopping.
• Oil pressure greater than the specified value applied to the check-ball in the oil jet valve opens the oil passage
to the spring-pressed nozzle, starting injection. Conversely, oil pressure less than the specified value applied to
the check-ball blocks the oil passage by spring force, stopping injection.
~------------------------------------.
SECTIONAL VIEW
OIL PASSAGE
CHECK BALL --1---111.
SPRING
OIL PASSAGE
(TO NOZZLE)
DCG111ZTB004
01-118-6
COOLING SYSTEM [WL-C, WE-C]
01-128 COOLING SYSTEM [WL-C, WE-C]

COOLING SYSTEM OUTLINE RADIATOR, COOLING SYSTEM CAP
[WL-C, WE-C] ........•........... 01-12B-1 CONSTRUCTION [WL-C, WE-C] ..... ~01-12B-2
COOLING SYSTEM STRUCTURAL THERMOSTAT CONSTRUCTION!
VIEW [WL-C, WE-C] .••....•...•... 01-12B-1 OPERATION [WL-C, WE-C] .........• 01-12B-3
COOLING SYSTEM WATER PUMP CONSTRUCTION!
FLOW DIAGRAM [WL-C, WE-C] ••.•• 01-12B-2 OPERATION [WL-C, WE-C] ........•. 01-12B-3
COOLING FAN CONSTRUCTION
[WL-C, WE-C] .•.•........•.....•.. 01-12B-4
COOLING SYSTEM OUTLINE [WL-C, WE-C]

Features
COOLING SYSTEM STRUCTURAL VIEW [WL-C, WE-C]

dcf01120000Dt05
COOLING
SYSTEM CAP
COOLING FAN
COOLANT
RESERVE TANK
DCG112ZTB005
01-128-1
COOLING SYSTEM FLOW DIAGRAM [WL-C, WE-C]
dcf011200000t06
(
IEGR I III CYLINDER HEAD
1\
COOLER I .,. I
COOLANT
RESERVE I
I I
TANK
! -.
THERMOSTAT
CYLINDER BLOCK
TURBOCHARGER
RADIATOR r-' ~ I r+
+-
WATER PUMP r--1
I OIL COOLER
-+COOLANT
l J
FLOW
I HEATER* I
DIRECTION I I
*: IF EQUIPPED
arnffn00000142
RADIATOR, COOLING SYSTEM CAP CONSTRUCTION [WL-C, WE-C]

dcf011215200t02
A corrugated fin type radiator has been adopted.
The radiator tanks are made of plastic and the
core is made of aluminum for weight reduction. ~[(O)D~ 8WII
The down-flow direction of water inside the
radiator causes air to bleed from the cooling COOLING SYSTEM CA~
system easier.
Four mounting rubbers are utilized to decrease
vibration.
A low-pressure type cap has been adopted for the
cooling system. It is installed on the radiator.
(\l 0
\ ~
TANK CORE
DCG112ZTB001
01-128-2
THERMOSTAT CONSTRUCTION/OPERATION [WL-C, WE-C]
dcf011215171t02
Construction
• A wax-type thermostat with a jiggle-pin has been adopted.
• The thermostat body is made of stainless steel with excellent corrosion resistance.
Operation
• When the engine coolant temperature reaches
80-84 °C {176-183 OF}, the valve starts
opening to allow engine coolant to flow from the
radiator stabilizing the engine coolant
temperature. When the engine coolant
temperature decreases to approx. 77 °C {171°F}, LOWER RADIATOR ENGINE
the valve closes to stop the engine coolant flow HOSE SIDE SIDE
from the radiator.
. . . ENGINE COOLANT
FLOW DIRECTION
WATER PUMP CONSTRUCTION/OPERATION [WL-C, WE-C]

Construction
• The aluminum alloy water pump with the impeller built into the cylinder block has been adopted for size
reduction.
• A highly reliable integrated water seal has been adopted.
• The water pump is not serviceable and must be replaced as a single unit if it has a malfunction.
EXTERNAL VIEW SEC.A-A
WATER SEAL
IMPELLER
DCG 112ZTB003
Operation
• The water pump is driven by the drive belt.
01-128-3
COOLING FAN CONSTRUCTION [WL-C, WE-C]
dcf01121514ot02
• A thermo-modulation type cooling fan has been adopted which operates the cooling fan only when necessary.
Due to this, the following effects have been obtained.
Reduced noise
- Improved heating performance
- Rapid engine warming-up
• The cooling fan consists of the fan blades and fan drive.
• Noise (wind noise) which occurs during fan operation has been reduced due to the nonuniform positioning of
the fan blades.
• The fan blades are made of plastic for weight reduction.
• The cooling fan is driven by the drive belt.
FAN BLADE
DCG112ZTB004
Cooling fan specification

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

INTAKE AIR SYSTEM OUTLINE TUR80CHARGER CONSTRUCTIONI
[WL-C, WE-C] ...........••....•.. 01-138-1 OPERATION [WL-C, WE-C] ..••...... 01-138-5
INTAKE AIR SYSTEM STRUCTURAL CHARGE AIR COOLER
VIEW [WL-C, WE-C] •...•...•..•.•. 01-138-2 CONSTRUCTION [WL-C, WE-C] ....•• 01-138-6
INTAKE AIR SYSTEM HOSE ACCELERATOR PEDAL COMPONENT
ROUTING DIAGRAM CONSTRUCTION [WL-C, WE-C] ..••.. 01-138-6
[WL-C, WE-C] .........••.....•... 01-138-2 GLOW SYSTEM OUTLINE
INTAKE AIR SYSTEM DIAGRAM [WL-C, WE-C] ..............•.•.... 01-138-6
[WL-C, WE-C] •••.•....••...•.•..• 01-138-3 GLOW SYSTEM CONSTRUCTION
AIR CLEANER CONSTRUCTION [WL-C, WE-C] •.•..........•...... 01-138-6
[WL-C, WE-C] •••.•.....•.....•... 01-138-3 GLOW SYSTEM OPERATION
VARIA8LE 800ST CONTROL (V8C) [WL-C, WE-C] •.........•......... 01-138-6
SOLENOID VALVE FUNCTION GLOW PLUG FUNCTION
[WL-C, WE-C] .•............•••... 01-138-3 [WL-C, WE-C] ••.....•..••.......•. 01-138-6
VARIA8LE 800ST CONTROL (V8C) GLOW PLUG CONSTRUCTION
SOLENOID VALVE CONSTRUCTION [WL-C, WE-C] .•.........•......•. 01-138-7
[WL-C, WE-C] ...•..•........•.... 01-138-3 GLOW PLUG RELAY OPERATION
AIR CHARGING SYSTEM OUTLINE [WL-C, WE-C] ...•.•.•••.•....•..• 01-138-7
[WL-C, WE-C] . . . . . . . . . . . . . . . • . . . . 01-138-4 VACUUM CHAM8ER FUNCTION
AIR CHARGING SYSTEM DIAGRAM [WL-C, WE-C] ......•.•..........• 01-138-7
[WL-C, WE-C] .....••.•........... 01-138-4 VACUUM CHECK VALVE FUNCTION
AIR CHARGING SYSTEM OPERATION [WL-C, WE-C] ..............•...... 01-138-7
[WL-C, WE-C] ......•............. 01-138-4 VACUUM CHECK VALVE
TUR80CHARGER FUNCTION CONSTRUCTION [WL-C, WE-C] ••.... 01-138-8
[WL-C, WE-C] .......•...•........ 01-138-5
INTAKE AIR SYSTEM OUTLINE [WL-C, WE-C]

dcf011300000to5
Features
IPower efficiency, performance, and fuel economy I• A variable geometry turbocharger has been adopted
Specification
Item WL-C, WE-C
Turbocharger type Variable geometry turbocharger
Air cleaner element Dry type
Glow plug type Stainless type
01-138-1
INTAKE AIR SYSTEM STRUCTURAL VIEW [WL-C, WE-C]
dcf01130000ot06
ACCELERATOR PEDAL COMPONENT VACUMM CHECK VALVE

(
BLADE ACTUATOR
DUCT
GLOW PLUG RELAY
DBGl13BTBB05
INTAKE AIR SYSTEM HOSE ROUTING DIAGRAM [WL-C, WE-C]

dcf01130000ot07
VACUUM CHECK VALVE

AIR FILTER
EGRVALVE
INTAKE SHUTTER
SOLENOID VALVE
(HALF)
INTAKE SHUTTER
SOLENOID VALVE
(FULL)
EGR CONTROL INTAKE SHUTTER VALVE
SOLENOID VALVE
VACUUM PUMP
DBGl13BWB305
01-138-2
INTAKE AIR SYSTEM DIAGRAM [WL-C, WE-C]
dcf01130000Qt08
CHARGE AIR COOLER
INTAKE MANIFOLD
- *:TOPCM
DGB113BTB001
AIR CLEANER CONSTRUCTION [WL-C, WE-C]

dcf011313300t02
• Consists of the air cleaner case, air cleaner element, and fresh-air duct.
• A dry type air cleaner element has been adopted. r---------------------,
DGB113BTB002
VARIABLE BOOST CONTROL (VB C) SOLENOID VALVE FUNCTION [WL-C, WE-C]

dcf011318748t01
• Switches the vacuum passage between the vacuum chamber and the guide blade actuator.
• Vacuum is applied to the guide blade actuator using the VBC solenoid valve.
• As a result, the variable guide vanes of the turbocharger are adjusted based on the signals from the PCM.
VARIABLE BOOST CONTROL (VBC) SOLENOID VALVE CONSTRUCTION [WL-C, WE-C]

dcf011318748to2
Construction
• Consists of the solenoid coil, spring, and plunger.
PORT A (VACUUM CHAMBER)
PORT B (GUIDE BLADE ACTUATOR)
DBG113BTB311
01-138-3
AIR CHARGING SYSTEM OUTLINE [WL-C, WE-C]
dcf01131370ot04
• A variable boost (variable geometry) type turbocharger has been adopted. By changing the opening angle of
the guide blades and changing the exhaust pressure that acts on the turbine impellers, the optimum boost
pressure according and fuel consumption have been improved in every driving range. c'
AIR CHARGING SYSTEM DIAGRAM [WL-C, WE-C]
dcf01131370ot05
VACUUM CHECK VALVE

CHAMBER
VACUUM PUMP
- *:TOPCM
DBG113BTB702
AIR CHARGING SYSTEM OPERATION [WL-C, WE-C]

dcf01131370ot06
• When the VBC solenoid valve is operated according to the duty signal from the PCM, the vacuum passage is
opened and vacuum is applied to the guide blade actuator of the turbocharger. Due to this, the rod of the guide
blade actuator is pulled and the opening angle of the guide blades changes.
• When the duty signal is on for a long time, the vacuum that acts on the guide blade actuator is reduced and the
guide blades move in the closing direction.
• When the duty signal is off for a long time, the vacuum that acts on the guide blade actuator is reduced and the
guide blades move in the opening direction.
• When the guide blades are moved in the closing direction, the passages that lead the exhaust gas to the
turbine impellers become narrow and the flow rate of the exhaust gas increases. Due to this, the exhaust gas
pressure is increased and the boost pressure is also increased. On the other hand, when the guide blades are
moved in the opening direction, the passages that lead the exhaust gas to the turbine impellers become wide.
Due to this, the exhaust gas pressure is reduced and the boost pressure is also reduced.
01-138-4
GUIDE BLADE CLOSED GUIDE BLADE OPEN

(BOOST PRESSURE IS LOW) (BOOST PRESSURE HIGH)
TURBINE IMPELLER
TURBOCHARGER FUNCTION [WL-C, WE-C]

dcf011313700t07
• The turbocharger uses the exhaust gas pressure to compress the intake air.
TURBOCHARGER CONSTRUCTION/OPERATION [WL-C, WE-C]

dcf01131370Dt08
• A variable geometry turbocharger has been adopted.

• The turbocharger consists of mainly a turbine wheel, a compressor wheel, guide blades, and a guide blade
actuator.
• When the exhaust gas flows to the turbine wheel, the turbine wheel and the compressor wheel that is on the
same axis as the turbine wheel rotate to compress the intake air.
• The opening angle of the guide blades changes according to the movement of the guide blade actuator rod.
0+
o
¢ INTAKE AIR FLOW
• EXHAUST GAS FLOW
DBG113BTB396
01-138-5
CHARGE AIR COOLER CONSTRUCTION [WL-C, WE-C]
dcf011313560t02
• An aluminium-alloy intercooler has been adopted.

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

dcf01134160Ot02
• Consists of the accelerator pedal and accelerator

ACCELERATOR
pedal position (APP) sensor. PEDAL POSITION
(APP) SENSOR
IDLE SWITCH
ACCELERATOR
PEDAL
DGB113BTB004
GLOW SYSTEM OUTLINE [WL-C, WE-C]

dcf011318601t07
• The glow system warms up the combustion chamber at engine start to improve ignitability.
GLOW SYSTEM CONSTRUCTION [WL-C, WE-C]

dcf011318601t08
• The glow system consists of the glow plug relay, glow plug lead, and glow plug.
GLOW SYSTEM OPERATION [WL-C, WE-C]

dcf011318601t09
• When the PCM energizes the glow plug relay, the glow plug activates, the circuit from the battery to the glow
plug is established, and power is supplied to the glow plug via the glow plug lead. Due to this, the glow plug is
heated and the combustion chamber is warmed up.
GLOW PLUG
DGB113BTB005
GLOW PLUG FUNCTION [WL-C, WE-C]

dcf011318601t10
• The glow plug warms up the air inside the combustion chamber by generating heat.
01-138-6
GLOW PLUG CONSTRUCTION [WL-C, WE-C]
dcf011318601t11
• Installed to the cylinder head.

• A stainless type glow plug has been adopted.
q@L--J..I-!!1---IL-l!-------l~ ~~
HEAT-GENERATING AREA
GLOW PLUG RELAY OPERATION [WL-C, WE-C]

dcf011318601t12
• The glow plug relay activates according to the glow control signal from the peM, and supplies/cuts the power to
the glow plug.
DBG113ATB105
VACUUM CHAMBER FUNCTION [WL-C, WE-C]

dcf011320330101
• The vacuum chamber improves vacuum

efficiency by reducing the pulsation generated TO VACUUM PUMP
when the air is drawn.
TOEGR
SOLENOID VALVE
VACUUM CHAMBER
DBG 113BTB302
VACUUM CHECK VALVE FUNCTION [WL-C, WE-C]

dcf01134291 0101
• The one-way check valve prevents vacuum pressure inside the vacuum pump from flowing back to the vacuum
chamber.
01-138-7
VACUUM CHECK VALVE CONSTRUCTION [WL-C, WE-C]
dcf011342910to2
• Mainly consists of the valve.

A
SEC. A-A
TO
VACUUM"
PUMP
~AIRFLOW
DBG113BTB301
01-138-8
FUEL SYSTEM [WL-C, WE-C]
·01-148 FUEL SYSTEM [WL-C, WE-C]

FUEL SYSTEM OUTLINE SUPPLY PUMP CONSTRUCTION/
[WL-C, WE-C] .................... 01-148-1 OPERATION [WL-C, WE-C] .......... 01-148-5
FUEL SYSTEM STRUCTURAL VIEW FUEL METERING VALVE
[WL-C, WE-C] .................... 01-148-2 FUNCTION [WL-C, WE-C] ........... 01-148-9
FUEL SYSTEM DIAGRAM FUEL METERING VALVE
[WL-C, WE-C] .................... 01-148-3 CONSTRUCTION/OPERATION
COMMON RAIL INJECTION [WL-C, WE-C] .................... 01-148-9
SYSTEM FUNCTION COMMON RAIL FUNCTION
[WL-C, WE-C] .................... 01-148-4 [WL-C, WE-C] ..................... 01-148-1 0
FUEL TANK CONSTRUCTION COMMON RAIL CONSTRUCTION
[WL-C, WE-C] .................... 01-148-4 [WL-C, WE-C] .................... 01-148-10
FUEL FILTER FUNCTION FUEL INJECTOR FUNCTION
[WL-C, WE-C] .................... 01-148-4 [WL-C, WE-C] ..................... 01-148-10
FUEL FILTER CONSTRUCTION/ FUEL INJECTOR CONSTRUCTION
OPERATION [WL-C, WE-C] ......... 01-148-5 [WL-C, WE-C] ..................... 01-148-10
SUPPLY PUMP FUNCTION FUEL INJECTOR OPERATION
[WL-C, WE-C] .................... 01-148-5 [WL-C, WE-C] ..................... 01-148-12
CHECK VALVE FUNCTION
[WL-C, WE-C] .................... 01-148-13
FUEL SYSTEM OUTLINE [WL-C, WE-C]

dcf01140000Ot04
Features
IImproved exhaust gas purification Common rail injection system adopted
Specification
Item WL-C, WE-C
Supply pump Electronic control
Fuel injector Electromagnetic control
Fuel tank capacity (reference) (L {US gal, Imp gal}) 70 {18, 15}
01-148-1
FUEL SYSTEM STRUCTURAL VIEW [WL-C, WE-C)
dcf01140000Ot05
Engine Room Side
CHECK VALVE
FUEL INJECTOR
COMMON RAIL
SEDIMENTOR SWITCH
FUEL METERING VALVE

SUPPLY PUMP
DBG114BTB302
Fuel Tank Side

Double cab 4x2 (except Hi-Rider), Stretch cab 4x2 (with rear access system (except Hi-Rider»
FUEL GAUGE SENDER UNIT
FUEL TANK
DBG114BTB330
01-148-2
Regular cab 4x4, stretch cab 4x4 (with rear access system), Hi-Rider
FUEL SYSTEM DIAGRAM [WL-C, WE-C]
- *:TOPCM
- - - . - : FUEL FLOW
DBGl14BTB301
01-148-3
COMMON RAIL INJECTION SYSTEM FUNCTION [WL-C, WE-C]
dcf01140000Dt07
This system stores fuel under high pressure supplied by the supply pump in the common rail, and injects it
through the electromagnetic injectors.
The PCM controls both fuel injection amount and timing by sending a signal to the injector solenoid valve coil.
Since fuel is highly pressurized by the supply pump and stored in the common rail, injection pressure is
constantly assured even at low speed since engine speed and load have no influence on the injection process.
The PCM can precisely control the fuel injection amount and timing due to use of an solenoid valve coil in the
injector that opens and closes the fuel path.
Fuel is injected multiple times, including multiple auxiliary injections previous to the main injection. These
multiple injections help to smooth the fuel combustion process, reducing noise and vibration levels as well as
the amount of NOx in the exhaust.
With the use of 160 MPa {1.632 kgf/cm 2 , 23,206 psi} ultra-high pressure injectors, engine output is improved
and the amount of smoke and particulate matter in the exhaust is greatly reduced.
<::=
......
FUEL PRESSURE LIMITER
FUEL
PRESSURE
SENSOR
COMMON RAIL
FUEL FILTER
t
FUEL TANK FUEL INJECTOR ~
=:> RETURN FUEL FLOW

"-------:0
...... MAIN FUEL FLOW
DBG114BTB30B
FUEL TANK CONSTRUCTION [WL-C, WE-C]

dcf011442110to2
Capacity is 70 L {18 US gal, 15 Imp gal}.

Two rollover valves are built-in.
FUEL FILTER FUNCTION [WL-C, WE-C]

dcf01142049Dt03
The filter part removes foreign material or dirt in the fuel.

The priming pump is a pump to discharge (drain) the accumulated water efficiently.
01-148-4
FUEL FILTER CONSTRUCTION/OPERATION [WL-C, WE-C]
dcf011420490t04
• The fuel filter consists of the drain plug and the priming pump.
• To drain water, loosen the drain plug on the lower side and pump the priming pump on the upper side of the
fuel filter.
• The sedimentor switch illuminates the sedimentor warning light to inform the user of the drain timing. The float
rises according to the level of accumulated water. If the water level exceeds the specification, the circuit for the
sedimentor switch is completed.
PRIMING PUMP
FUEL FILTER
CARTRIDGE
SEDIMENTOR
SWITCH DRAIN PLUG
D8G 1148T8307
SUPPLY PUMP FUNCTION [WL-C, WE-C]

dcf01141335ot01
• An electrically controlled supply pump with ultra-high discharge pressure and low-drive torque has been
adopted.
• The supply pump intakes the proper fuel amount and pressure feeds the fuel to the common rail.
SUPPLY PUMP CONSTRUCTION/OPERATION [WL-C, WE-C]

dcf01141335ot02
• The supply pump is driven by the timing belt. The feed pump is driven by the supply pump drive shaft.
• The supply pump has three pumping elements with 120 0 offset (displacement pumps).
• The fuel metering valve is located in the supply duct between the feed pump and the supply pump, and meters
the quantity of fuel which is to be delivered into the high-pressure chamber in accordance with the current
operating status of the engine.
• Any surplus fuel is returned to the fuel tank via the fuel return ..
,-------------------------------------,
FUEL RETURN
SUPPLY
PUMP
. FEED PUMP
D8G 1148T8502
01-148-5
1
Flow of fuel through fuel pump
PRESSURE RESTRICTION
(ZERO DELIVERY RESTRICTION)
(
HIGH FUEL
PRESSURE SUPPLY PUMP
r--::=>-L-_OVER FLOW
VALVE
TO FUEL
INJECTOR~-f----+H
FUEL FILTER
FUEL METERING VALVE
FUEL TANK
DBG114BTB509
Feed Pump Operation

• The feed pump is designed as a gear pump and delivers the required fuel to the supply pump.
Essential components are two counter-rotating, meshed gear wheels that transport the fuel in the tooth gaps
from the intake side to the pressure side.
The contact line of the gears forms a seal between the intake side and the pressure side and prevents the fuel
from flowing back.
The delivery quantity is approximately proportional to engine speed. For this reason, fuel-quantity control is
required.
For fuel-quantity control purposes, there is an overflow valve incorporated in the supply pump.
INTAKE SIDE
":FUELFLOW
DBG114BTB510
\. ,
01-148-6
Overflow Valve Operation
• High-pressure generation (up to 160 MPa {1,632 kgf/cm2, 23,206 psi}) means high thermal load on the
individual components of the supply pump. The mechanical components of the supply pump must also be
lubricated sufficiently to ensure durability.
The overflow valve is designed to ensure optimum lubrication or cooling for all operating conditions.
At lower engine speeds (low feed pump pressure) the control plunger is moved only slightly out of its seat. The
lubrication/cooling requirement is correspondingly low.
A small amount of fuel is released to lubricate/cool the pump via the restriction at the end of the control plunger
The supply pump features automatic venting. Any air in the supply pump is vented through the restriction.
With increasing engine speed (increasing feed pump pressure), the control plunger is moved further against
the compression spring.
Increasing engine speeds require increased cooling of the supply pump. Above a certain pressure, the supply
pump cooling bypass is opened and the flow rate through the supply pump is increased.
At high engine speeds (high feed pump pressure), the control plunger is moved further against the
compression spring. The supply pump cooling bypass is now fully open (maximum cooling).
Excess fuel is transferred via the return bypass to the intake side of the feed pump.
L
In this way, the internal pump pressure is limited to a maximum of 600 kPa {6.12 kgf/cm2, 87.0 psi}.
LOW FUEL INCREASING FUEL HIGH

FUEL ENGINE PUMP ENGINE PUMP ENGINE
PUMP
SPEED PRESS-'--_ _-.t SPEED PRESS- '--_ _-.. SPEED
PRESS-
URE TIME URE TIME
URE TIME
LUBRICATION! LUBRICATION!
COOLINGNENT COOLINGNENT
ILATION- ILATION-
SUPPLY PUMP SUPPLY PUMP
RESTRICTION
SUPPLY
PUMP
COOLING
CONTROL SUPPLY BYPASS
PLUNGER PUMP
COOLING
BYPASS RETURN
BYPASS TO
FEED PUMP
TO HIGH- TO HIGH-
TO HIGH-
PRESSURE PRESSURE PRESSURE
CHAMBER CHAMBER
CHAMBER
DBG114BTB511
01-148-7
High Pressure Generation
• The supply pump is driven via the drive shaft.
An eccentric element is fixed to the drive shaft and moves the three plungers up and down according to the
cam lobes of the eccentric element.
Fuel pressure from the feed pump is applied to the inlet valve. If the feed pump pressure exceeds the internal
pressure of the high-pressure chamber (pump plunger in TOG position), the inlet valve opens.
Fuel is now pressed into the high-pressure chamber, which moves the pump plunger downwards (intake
stroke).
If BOG of the pump plunger is exceeded, the inlet valve closes due to the increasing pressure in the
high"pressure chamber. The fuel in the high-pressure chamber can no longer escape.
As soon as the pressure in the high-pressure chamber exceeds the pressure in the common rail, the outlet
valve opens and the fuel is pressed into the common rail via the high-pressure connection (delivery stroke).
The pump plunger delivers fuel until TOG is reached. After this, the pressure drops so that the outlet valve
closes.
As the pressure on the remaining fuel is reduced, the pump plunger moves downward.
If the pressure in the high-pressure chamber falls below the transfer pressure, the inlet valve reopens and the
process starts again.
HIGH-PRESSURE TO COMMON RAIL
INLET VALVE
~.-...--TAPPET
. . . . FUEL FEED
DBG114BTBR12
01-148-8
Zero Delivery Restriction Operation
• The zero-delivery throttle is installed to the supply
pump. The fuel metering unit sends a quantity of
ZERO DELIVERY THROTTLE
fuel to the plunger even during zero-delivery. To
prevent this, the fuel is returned to the feed pump
inlet via the orifice of the zero-delivery throttle, ZERO DELIVERY ORIFICE
ensuring zero fuel delivery to the plunger. Except
during zero-delivery, essentially no fuel is sent to
the orifice due to the throttle effect, instead it is
sent to the plunger.
FUEL METERING VALVE FUNCTION [WL-C, WE-C]

dcf01141335ot03
• By controlling the supply pump intake amount, the fuel metering valve controls the pressure pump feed amount
and the pressure inside the fuel injection pipe.
• The intake amount is determined by the total opening size of the valve as controlled by the duty value of the
solenoid actuation current.
• The duty solenoid can adjust the open and close time ratio to control the intake amount by changing the OFF
time during a single cycle. For a normally open type fuel metering valve, making the duty ratio larger increases
the intake amount and, conversely, making the duty value smaller decreases the intake amount.
I I I
j Duty j j
il 'j j-'---
U U
ON (CLOSE)
OFF (OPEN)
j I
I
j 1 cycle
.j,-,-----
i i
DBG114BTB514
FUEL METERING VALVE CONSTRUCTION/OPERATION [WL-C, WE-C]

dcf011413350to4
De-energized (open)
• The solenoid inner port is opened and fuel is sent
into the high-pressure chamber.
.....FUELFLOW
DBG 114BTB506
01-148-9
Energized (closed)
• The solenoid inner port is closed. Fuel siphoned
by the feed pump is returned to the fuel tank
through the overflow valve.
DBG114BTB507
COMMON RAIL FUNCTION [WL-C, WE-C]

dcf011413151t01
• Due to constant high-pressure fuel (25-160 MPa {255-1.631 kgf/cm2, 3,626-23,206 psi}) in the rail,
electrically controlled injection is made possible.
COMMON RAIL CONSTRUCTION [WL-C, WE-C]

dcf011413151t02
• The PCM constantly maintains optimum pressure by monitoring the fuel pressure measurement signal from the
fuel pressure sensor.
• As a consideration to safety, a fuel pressure limiter has been installed to mechanically drain fuel if the pressure
goes above 195 MPa {1.988 kgf/cm2, 28,282 psi}.
CONNECTOR(FUEL INJECTOR SIDE)
CONNECTOR(SUPPLY PUMP SIDE)

DBG114BTB505
FUEL INJECTOR FUNCTION [WL-C, WE-C]

dcf011413250t01
• A small sized, energy saving, electromagnetically controlled injector has been adopted.
• A multiple fuel injection system has been adopted. The fuel injection amount and timing, as well as the division
of the numerous injections are according to a PCM ON/OFF signal that controls the opening and closing of the
electromagnetic valves.
• The construction and material of the electromagnetic valve has been modified to save energy and improve
response.
FUEL INJECTOR CONSTRUCTION [WL-C, WE-C]

dcf01141325Ot02
• The fuel injector is composed of: a valve control plunger that controls the nozzle, a control chamber with an
inflow/outflow orifice, and an solenoid valve coil that controls the inflow/outflow of fuel to the control chamber
via an on/off function.
• The valve control plunger is connected to the nozzle so that the up and down movement of the plunger results
in the opening and closing of the nozzle.
• The control chamber contains a single orifice plate to provide an inflow and outflow path.
01-148-10
RETURN FUEL FLOW (TO FUEL TANK)
t
FUEL FLOW (FROM COMMOMRAIL)
ORIFICE PLATE
VALVE CONTROL PLUNGER
NOZZLE
DBG114BTB500
Fuel Injector Calibration Code

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

CALIBRATION BAR CODE
INJECTOR
DBG 114BTB503
01-148-11
FUEL INJECTOR OPERATION [WL-C, WE-C]
dcf011413250to3
• The solenoid valve coil controls inflow/outflow of fuel to the control chamber by opening and closing according
to an ON/OFF signal received from the peM.
De-energized (off)
- When the solenoid valve coil is not energized, the plate is pushed down, closing the control chamber outflow
orifice to valve ball, and causing the pressurized fuel from the fuel injection pipe to fill the control chamber. Due
to this, the nozzle connected to the valve control plunger is closed and injection does not occur.
Energized (on)
When solenoid valve coil energization begins the valve ball and plate are pulled upwards, opening the control
chamber outflow orifice and fuel outflow occurs. As fuel outflow occurs, the control chamber pressure
decreases, drawing the valve control plunger and the nozzle upward, and injection begins. As energization
continues the nozzle is opened even more, providing maximum injection rate. When energization of the
solenoid valve coil ends, the plate once again moves down and the nozzle is closed instantaneously. Since the
coil can be repeatedly energized any number of times, multiple pilot injection is made possible.
ENERGIZED (ON)
RETURN
FUELFrL~O~W~-T'-~__'
PLATE
VALVE BALL OUTFLOW

ORIFICE
CONTROL
CHAMBER
IN-FLOW
ORIFICE
VALVE CONTROL
PLUNGER
NOZZLE
+: FYEL FLOW
DBG114BTB501
01-148-12
CHECK VALVE FUNCTION [WL-C, WE-C]
dcf011413152t01
• The one-way check valve prevents fuel from flowing back to the fuel injector.
CHECK VALVE
FUEL RETURN HOSE

TO FUEL ~ FROM
TANK .~. i~~~TOR
• : FUEL FLOW
DBG114BTB111
01-148-13
EXHAUST SYSTEM [WL-C, WE-C]
01-158 EXHAUST SYSTEM [WL-C, WE-C]

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

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

EMISSION SYSTEM OUTLINE EGR CONTROL SOLENOID VALVE
[WL-C, WE-C] .................... 01-168-1 DESCRIPTION [WL-C, WE-C] .....•. 01-168-5
EMISSION SYSTEM STRUCTURAL EGR COOLER FUNCTION
VIEW [WL-C, WE-C] .•......•...... 01-168-2 [WL-C, WE-C] ...•..•...........••• 01-168-5
EMISSION SYSTEM DIAGRAM EGR COOLER DESCRIPTION
[WL-C, WE-C] ...•••••••...•...•.. 01-168-3 [WL-C, WE-C] ..•...•...•.........• 01-168-6
EGR SYSTEM OUTLINE INTAKE SHUTTER VALVE
[WL-C, WE-C] ...••.••••....•....• 01-168-4 DESCRIPTION [WL-C, WE-C] ...•...• 01-168-6
EGR SYSTEM DIAGRAM INTAKE SHUTTER SOLENOID VALVE
[WL-C, WE-C] ......••••....••...• 01-168-4 DESCRIPTION [WL-C, WE-C] ...•.... 01-168-6
EGR SYSTEM OPERATION OXIDATION CATALYTIC
[WL-C, WE-C] .......•.•.••.••.... 01-168-4 CONVERTER FUNCTION
EGR SYSTEM FUNCTION [WL-C, WE-C] ......•.....•....•..• 01-168-6
[WL-C, WE-C] .......•..•.•....... 01-168-4 OXIDATION CATALYTIC CONVERTER
EGR SYSTEM OPERATION CONSTRUCTION [WL-C, WE-C] .••..• 01-168-7
[WL-C, WE-C] ..•................. 01-168-5 OXIDATION CATALYTIC CONVERTER
EGR SORENOID VALVE OPERATION [WL-C, WE-C] .......... 01-168-7
FUNCTION [WL-C, WE-C] .......... 01-168-5 ROLLOVER VALVE FUNCTION
EGR SORENOID VALVE [WL-C, WE-C] ......•..........•... 01-168-7
DESCRIPTION [WL-C, WE-C] •••.... 01-168-5 ROLLOVER VALVE
EGR CONTROL SOLENOID VALVE CONSTRUCTION/OPERATION
FUNCTION [WL-C, WE-C] ...•..•... 01-168-5 [WL-C, WE-C] ...........•.......•. 01-168-7
EMISSION SYSTEM OUTLINE [WL-C, WE-C]

dcf011600000t04
Feature
• EGR system adopted
Improved exhaust gas purification • EGR cooler adopted
• Oxidation catalytic converter adopted
Specification
Item WL-C, WE-C
01-168-1
EMISSION SYSTEM STRUCTURAL VIEW [WL-C, WE-C]
dcf011600000to5
Engine Room Side

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

DBG116BTB331
01-168-2
Regular cab 4x4, stretch cab 4x4 (with rear access system), Hi-Rider
EMISSION SYSTEM DIAGRAM [WL-C, WE-C]
AIR FI
EGR CONTORL SOLENOID VALVE
EGR SOLENOID VALVE
INTAKE SHUTTER SOLENOID---!HI!:,II;li!-*

VALVE (HALF OPEN)
INTAKE SHUTTER SOLE

VALVE (FULL CLOSE)
-*:TOPCM
DBG116BWB332
01-168-3
EGR SYSTEM OUTLINE [WL-C, WE-C]
dcf011600020t06
• The EGR cooler cools EGR gas and improves the intake-air charging efficiency, reducing black smoke.
• For control of EGR system, refer to CONTROL SYSTEM, EGR CONTROL. (See 01-40B-17 EGR CONTROL
OUTLINE [WL-C, WE-C].) (See 01-40B-17 EGR CONTROL BLOCK DIAGRAM [WL-C, WE-C].) (See 01-40B-
17 EGR CONTROL OPERATION [WL-C, WE-C].)
EGR SYSTEM DIAGRAM [WL-C, WE-C]

dcf011600020t07
VALVE
EGR VALVE POSITION SENSOR

EGR CONTROL SOLENOID
EGR SOLENOID VALVE
- *:TOPCM
DGB116BTB723
EGR SYSTEM OPERATION [WL-C, WE-C]

dcf01160002ot08
• To open the EGR valve and increase the EGR amount, increase the EGR solenoid valve control duty valve to
increase the vacuum applied to the EGR valve. To close the EGR valve to decrease the EGR amount, increase
the EGR control solenoid valve control duty valve to decrease the vacuum applied to the EGR valve.
• When the PCM energizes the intake shutter solenoid valve during the exhaust gas introduction at low engine
speed, the vacuum passage is opened and vacuum is applied to the intake shutter valve actuator. Due to this,
the intake shutter valve is closed and vacuum is generated downstream of the intake manifold after the intake
shutter valve, realizing easier introduction of the exhaust gas to the combustion chamber.
EGR SYSTEM FUNCTION [WL-C, WE-C]

dcf011620300t03
• The EGR valve, installed to the intake manifold, recirculates the exhaust gas to the intake manifold.
01-168-4
EGR SYSTEM OPERATION [WL-C, WE-C]
dcf01162030Ot04
• Consists of a diaphragm and valves.
• The EGR solenoid valve operates based on the signal from the PCM and changes the valve opening angle to
open the passage leading from the exhaust gas to the intake manifold by inducting the vacuum to the
diaphragm on the upper part of the EGR valve.
DIAPHRAGM
FILTER
ROD I!!!!!JHI----HOLDER
VALVE
HOUSING ---LL...LJ
EGR SORENOID VALVE FUNCTION [WL-C, WE-C]

dcf011618741t05
• EGR solenoid valve open/close the passage which brings vacuum generated in the vacuum pump to the
diaphragm, and control the EGR valve opening.
EGR SORENOID VALVE DESCRIPTION [WL-C, WE-C]

dcf011618741t06
Structure/Operation
• Vent side port of solenoid valve is connected to the EGR valve diaphragm through EGR control solenoid valve,
and the vacuum side port of solenoid valve is connected to vacuum pump..
• Solenoid valve consists of a solenoid coil, spring, plunger and air filter.
• EGR solenoid valve increases the angle of the valve opening by increasing vacuum on EGR valve via the EGR
control signal (duty signal).
• EGR solenoid valve decreases the angle of the valve opening by releasing vacuum on EGR valve via the EGR
control signal (duty signal).
EGR CONTROL SOLENOID VALVE FUNCTION [WL-C, WE-C]

dcf011618741t07
• EGR valve changes the pressure on the diaphragm of the EGR valve from vacuum to atmospheric pressure.
EGR CONTROL SOLENOID VALVE DESCRIPTION [WL-C, WE-C]

dcf011618741to8
Structure/Operation
• EGR control solenoid valve consists of coil, spring, and plunger.
• When EGR valve is not energized, the passage between the diaphragm and atmospheric air side is open.
• When specified conditions are satisfied, the solenoid coils become energized and electromagnetic, and then
pull the plunger. At this time, the passage between the diaphragm and atmospheric air side is closed and the
passage between the diaphragm and vacuum pump side is opened.
EGR COOLER FUNCTION [WL-C, WE-C]

dcf011600020to9
• EGR cooler cools recircurated exhaust gas from the intake manifold.
01-168-5
-,
EGR COOLER DESCRIPTION [WL-C, WE-C]
dcf01160002ot10
Structure/Operation
• EGR cooler has an EGR passage and coolant passage.
..../
EGR COOLER
EXHAUST GAS FLOW

EGR PASSAGE
DBG116BTBB02
INTAKE SHUTTER VALVE DESCRIPTION [WL-C, WE-C]

dcf01160000ot07
Function
• When the exhaust gas recirculation system is operated, the intake shutter valve closes, vacuum is generated in
the intake manifold, and EGR gas is efficiently transported to the combustion chamber. As a result, NOx is
reduced.
• When the engine is idling, the intake shutter valve closes and reduces air intake noise.
Structure/Operation
• When the exhaust gas recirculation system is operated and vacuum is applied to the diaphragm of the intake
shutter valve actuator, internal lever is pulled and the intake shutter valve closes.
,---------------==----~--------------.
INTAKE MANIFOLD
DBG116BTBB01
INTAKE SHUTTER SOLENOID VALVE DESCRIPTION [WL-C, WE-C]

dcf01160000ot08
Function
• The intake shutter solenoid valve switches the opening/closing of the passage where the vacuum generated in
the vacuum pump is led to the diaphragm of the intake shutter valve actuator.
Structure
• The intake shutter valve consists mainly of a solenoid coil, and a spring, a plunger.
Operation .
• The vacuum passage between the intake shutter valve actuator and the vacuum pump is opened or closed
depending upon whether the intake shutter solenoid valve is energized or de-energized.
OXIDATION CATALYTIC CONVERTER FUNCTION [WL-C, WE-C]

dcf01162050ot04
• Purifies contaminants in the exhaust gas by utilizing a chemical reaction in a three way catalytic converter.
• The catalytic converter converts the noxious carbon monoxide and hydrocarbon in the exhaust gas to non-
noxious carbon dioxide and water.
01-168-6
OXIDATION CATALYTIC CONVERTER CONSTRUCTION [WL-C, WE-C]
dcf011620500to5
• Consists of a three-way catalytic converter and insulator.

• A catalytic converter utilizing a platinum-palladium-rhodium system has been adopted.
OXIDATION CATALYTIC CONVERTER OPERATION [WL-C, WE-C]

dcf01162050Ot06
• Contaminants in the exhaust gas (HC and CO) are purified by oxidization while passing through the catalytic
converter.
Oxidization process
• Noxious hydrocarbon (HC) and carbon monoxide (CO) are bonded to oxygen which is converted to
non-noxious carbon dioxide and water.
O2 + HC + CO ~ CO 2 + H2 0
ROLLOVER VALVE FUNCTION [WL-C, WE-C]

dcf01164272Ot03
• The rollover valve prevents fuel flow into the airflow hose during sudden cornering or vehicle rollover.
ROLLOVER VALVE CONSTRUCTION/OPERATION [WL-C, WE-C]

dcf01164272Ot04
• The rollover valve consists of a float, and spring.

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

(NORMAL VEHICLE POSITION) ROTATED 180 0 (VEHICLE
ROLLOVER)
... FLOW OF EVAPORATIVE GAS
DBG116ATB030
01-168-7
CHARGING SYSTEM [WL-3, WL-C, WE-C]
01-17 CHARGING SYSTEM [WL-3, WL-C, WE-C]

CHARGING SYSTEM OUTLINE CHARGING SYSTEM STRUCTURAL
[WL-3, WL-C, WE-C] •.........•... 01-17-1 VIEW [WL-3, WL-C, WE-C] .......... 01-17-1
GENERATOR CONSTRUCTION
[WL-3, WL-C, WE-C] ..•...•......•. 01-17-2
CHARGING SYSTEM OUTLINE [WL-3, WL-C, WE-C]

Features
IImproved reliability I• Generator with built-in battery sensing type Ie regulator adopted
CHARGING SYSTEM STRUCTURAL VIEW [WL-3, WL-C, WE-C]
BATTERY
DCG117ZTB003
01-17-1
CHARGING SYSTEM [WL-3, WL-C, WE-C]
GENERATOR CONSTRUCTION [WL-3, WL-C, WE-C]
dcf01171830Dt01
• A battery sensing type IC regulator is built into the generator which directly detects the voltage charged to the
battery. Battery overcharge during light loads and charge voltage decreases during heavy loads have been
prevented, improving battery reliability.
•
REAR BEARING
FRONT
BEARING
PULLEY
REGULATOR COMPONENT
STATOR COIL
DCG117ZTB001
GENERATOR
STATOR WARNING LIGHT
COIL
~-I---H-I---o E
BATTERY
IC REGULATOR
DCG117ZTB002
• An IC regulator with a malfunction diagnosis function is built into the generator. The generator warning light
illuminates if any of the following malfunctions occurs.
No power generation
Overvoltage
Open circuit "J
Terminal B disconnected
Terminal S disconnected
01-17-2
STARTING SYSTEM [WL-3, WL-C, WE-C]
01-19 STARTING SYSTEM [WL-3, WL-C, WE-C]

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

Features
IImproved startability I• Reduction type starter adopted
STARTING SYSTEM STRUCTURAL VIEW [WL-3, WL-C, WE-C]
DCG 119ZTB002
STARTER CONSTRUCTION [WL-3, WL-C, WE-C]

dcfOl1918400tol
• A high torque coaxial reduction type starter has been adopted.
~--------------------------------,
ENGINE SWITCH
B
PULL-IN COIL
DCGl19ZTBOOl
01-19-1
CONTROL SYSTEM [WL-C, WE-C]
01-408 CONTROL SYSTEM [WL-C, WE-C]

ENGINE CONTROL SYSTEM AlC CUT-OFF CONTROL
OUTLINE [WL-C, WE-C] ...•........ 01-408-2 8LOCK DIAGRAM [WL-C, WE-C] •..•• 01-408-18
ENGINE CONTROL SYSTEM AlC CUT-OFF CONTROL
STRUCTURAL VIEW [WL-C, WE-C] .. 01-408-3 OPERATION [WL-C, WE-C] ......•.•. 01-408-18
ENGINE CONTROL SYSTEM IMM081L1ZER SYSTEM
DIAGRAM [WL-C, WE-C] ••••••..... 01-408-4 OUTLINE [WL-C, WE-C] ..••..•..... 01-408-19
ENGINE CONTROL SYSTEM IMM081L1ZER SYSTEM 8LOCK
WIRING DIAGRAM [WL-C, WE-C] .... 01-408-5 DIAGRAM [WL-C, WE-C] ............ 01-408-19
ENGINE CONTROL SYSTEM IMM081L1ZER SYSTEM
8LOCK DIAGRAM [WL-C, WE-C] .... 01-408-9 OPERATION [WL-C, WE-C] ......••.. 01-408-19
ENGINE CONTROL SYSTEM PCM FUNCTION [WL-C, WE-C] ....... 01-408-19
RELATION CHART [WL-C, WE-C] •... 01-408-10 PCM CONSTRUCTION [WL-C, WE-C] .. 01-408-19
IDLE SPEED CONTROL OUTLINE MASS AIR FLOW (MAF) SENSOR
[WL-C, WE-C] ..•.........•......• 01-408-10 FUNCTION [WL-C, WE-C] ........... 01-408-20
IDLE SPEED CONTROL 8LOCK MASS AIR FLOW (MAF) SENSOR
DIAGRAM [WL-C, WE-C] ...•....... 01-408-11 CONSTRUCTION/OPERATION
IDLE· SPEED CONTROL [WL-C, WE-C] ..•......•.•.•...... 01-408-20
OPERATION [WL-C, WE-C] ......... 01-408-11 INTAKE AIR TEMPERATURE (IAT)
GLOW CONTROL OUTLINE SENSOR NO.2 FUNCTION
[WL-C, WE-C] ..•...•.•.•..•...... 01-408-11 [WL-C, WE-C] ..•..........•...... 01-408-21
GLOW CONTROL INTAKE AIR TEMPERATURE (IAT)
8LOCK DIAGRAM [WL-C, WE-C] .... 01-408-11 SENSOR NO.2 CONSTRUCTION/
GLOW CONTROL OPERATION OPERATION [WL-C, WE-C] •.•......• 01-408-21
[WL-C, WE-C] ...•....••...•.....• 01-408-12 INTAKE AIR TEMPERATURE (IAT)
800ST PRESSURE CONTROL SENSOR NO.1 FUNCTION
OUTLINE [WL-C, WE-C] •••..•...... 01-408-12 [WL-C, WE-C] ...•....•...•....•.•. 01-408-21
800ST PRESSURE CONTROL INTAKE AIR TEMPERATURE (IAT)
8LOCK DIAGRAM [WL-C, WE-C] .... 01-408-12 SENSOR NO.1 CONSTRUCTION/
800ST PRESSURE CONTROL OPERATION [WL-C, WE-C] ..••...... 01-408-22
OPERATION [WL-C, WE-C] ..•...... 01-408-12 800ST SENSOR FUNCTION
FUEL INJECTION AMOUNT CONTROL [WL-C, WE-C] •..•....•.......•.... 01-408-22
OUTLINE [WL-C, WE-C] •••..•...... 01-408-12 800ST SENSOR CONSTRUCTION/
FUEL INJECTION AMOUNT CONTROL OPERATION [WL-C, WE-C] ......••.. 01-408-22
8LOCK DIAGRAM [WL-C, WE-C] .... 01-408-13 ACCELERATOR PEDAL POSITION
FUEL INJECTION AMOUNT CONTROL (APP) SENSOR FUNCTION
OPERATION [WL-C, WE-C] ..•.•.... 01-408-13 [WL-C, WE-C] ...•...•...•.•....... 01-408-23
FUEL INJECTION TIMING CONTROL ACCELERATOR PEDAL POSITION
OUTLINE [WL-C, WE-C] ••..•.••... 01-408-13 (APP) SENSOR DESCRIPTION
FUEL INJECTION TIMING CONTROL [WL-C, WE-C] •••.•............... 01-408-23
8LOCK DIAGRAM [WL-C, WE-C] .... 01-408-14 IDLE SWITCH FUNCTION
FUEL INJECTION TIMING CONTROL [WL-C, WE-C] .••......•..•.•..•... 01-408-23
OPERATION [WL-C, WE-C] ..•.••.•. 01-408-14 IDLE SWITCH DESCRIPTION
MULTIPLE FUEL INJECTION [WL-C, WE-C] .••.........•....•••. 01-408-24
CONTROL OUTLINE [WL-C, WE-C] .. 01-408-15 FUEL TEMPERATURE SENSOR
MULTIPLE FUEL INJECTION CONTROL FUNCTION [WL-C, WE-C] .......... 01-408-24
8LOCK DIAGRAM [WL-C, WE-C] .... 01-408-15 FUEL TEMPERATURE SENSOR
MULTIPLE FUEL INJECTION CONTROL CONSTRUCTION/OPERATION
OPERATION [WL-C, WE-C] ......... 01-408-15 [WL-C, WE-C] .....•••............ 01-408-24
FUEL PRESSURE CONTROL FUEL PRESSURE SENSOR
OUTLINE [WL-C, WE-C] ••...•...... 01-408-16 FUNCTION [WL-C, WE-C] ..•..•..... 01-408-24
FUEL PRESSURE CONTROL FUEL PRESSURE SENSOR
8LOCK DIAGRAM [WL-C, WE-C] .... 01-408-16 CONSTRUCTION/OPERATION
FUEL PRESSURE CONTROL [WL-C, WE-C] ..........•••...•... 01-408-25
OPERATION [WL-C, WE-C] ......... 01-408-16 ENGINE COOLANT TEMPERATURE
EGR CONTROL OUTLINE (ECT) SENSOR FUNCTION
[WL-C, WE-C] . . . . . . • . • • • . . • . . . . .. 01-408-17 [WL-C, WE-C] .........•.•.•..•... 01-408-25
EGR CONTROL 8LOCK ENGINE COOLANT TEMPERATURE
DIAGRAM [WL-C, WE-C] .......•... 01-408-17 (ECT) SENSOR CONSTRUCTION/
EGR CONTROL OPERATION OPERATION [WL-C, WE-C] ..••...... 01-408-25
[WL-C, WE-C] . . . . . . . . • • . . . • . . . . .. 01-408-17 CAMSHAFT POSITION (CMP) SENSOR
AlC CUT-OFF CONTROL FUNCTION [WL-C, WE-C] ..••......• 01-408-25
OUTLINE [WL-C, WE-C] •.•......... 01-408-18
01-408-1
CAMSHAFT POSITION (CMP) SENSOR CLUTCH PEDAL POSITION (CPP)
CONSTRUCTION/OPERATION SWITCH FUNCTION [WL-C, WE-C] .. . 01-408-27
[WL-C, WE-C] . ................... 01-408-26 CLUTCH PEDAL POSITION (CPP)
CRANKSHAFT POSITION (CKP) SWITCH DESCRIPTION
SENSOR FUNCTION [WL-C, WE-C] .. 01-408-26 [WL-C, WE-C] . ................... . 01-408-28
CRANKSHAFT POSITION (CKP) NEUTRAL SWITCH FUNCTION
SENSOR CONSTRUCTION/ [WL-C, WE-C] . ................... . 01-408-28
OPERATION [WL-C, WE-C] ......... 01-408-27 NEUTRAL SWITCH CONSTRUCTION/
EGR VALVE POSITION SENSOR OPERATION [WL-C, WE-C] .......... 01-408-28
FUNCTION [WL-C, WE-C] .......... 01-408-27
ENGINE CONTROL SYSTEM OUTLINE [WL-C, WE-C]

dcf01400000ot22
Features
• Fuel injection control changed
Improved emission gas purification
• EGR control (and intake shutter valve control) adopted
Specification
Item . Specification
MAF sensor Hot-wire
Boost sensor Piezoelectric element
CMP sensor Hall element type
BARO sensor (built into PCM) Piezoelectric element
Fuel pressure sensor Piezoelectric element
CPP switch ON/OFF
Idle switch ON/OFF
01-408-2
ENGINE CONTROL SYSTEM STRUCTURAL VIEW [WL-C, WE-C]
dcf01400000ot23
GLOW
INDICATOR
LIGHT
APP SENSOR
IDLE
SWITCH
CPPSWITCH
BRAKE SWITCH
CKP SENSOR
PCM (BUILT INTO BARO
SENSOR)
MAF SENSOR!
IAT SENSOR NO.2
AlC RELAY FUEL PRESSURE SENSOR
SUPPLY PUMP
GLOW PLUG RELAY
BOOST SENSOR!
IAT SENSOR NO.1
DBG140BTB001
01-408-3
ENGINE CONTROL SYSTEM DIAGRAM [WL-C, WE-C]
dcf014000000t24
...J
:;:J: J: J: Z
w ~
[jd:~
() ()
z I,
;:: ;:: e.
f- f-
0:3;
Cl l.
C\I Ci)
zUJ UJ
...J
UJ
0 0
:;;:~
~,. 0,
...J W
:2_ ~
0: W UJ
,Cl
,z f- , ,
, , w
(L
UJ ::J
z, ,,, ,,,
::J III
,,
, w W z
,,
...J
,, ,, ,, J: () ~
,,
,
()
- *:TOPCM , , ," , w ,,
,___ _ , ,, ,, , ,---_ >..,
TACHOMETER ---':
,,
___ I
~:FUELFLOW I .. ____ I
GLOW INDICATOR LIGHT -j L__ ,-1--,-'-'-.!......I--'-:";: -----,

1___ -
---- CPP SWITCH

---- AlC RELAY
EGRVALVE
AIRFI
EGR CONTROL SOLENOID
EGR SOLENOID
TO GLOW PLUG
INTAKE SHUTTER SOLENOI
VALVE (HALF OPEN)
INTAKE SHUTTER SOLENOID
VALVE (FULL CLOSE)
APP IDLE
SENS~CH
\ . "
ACCELERATOR
PEDAL
P SENSOR
BOOST SENSOR/IAT SENSOR NO.1
TO VACUUM RESERVER TANK

FOR BRAKE SYSTEM
DBG140BTB002
01-408-4
ENGINE CONTROL SYSTEM WIRING DIAGRAM [WL-C, WE-C]
dcf014000000t25
-r--t--tLOCK
ACC
IG1
-r--t----{E
IG2
STA DLC
IG-
FEN
KLN
TEN
F
DLC-2
KLN
'----;TEN
PCM
(BUILT INTO
GLOW INDICATOR
LIGHT r--+-----t---------{ BARO SENSOR)
VEHICLE
SPEED SIGNAL
FUEL
INJECTOR
FUEL
INJECTOR
NO.3
FUEL
INJECTOR
NO.2
FUEL
INJECTOR
NO.1
DBG102BWBY01
01-408-5
..,
RFWLOCK i .
SOLENOID (0
APP )--+-+.1' VALVE
SENSOR
RFW FREE
SOLENOID
.)---+.1' VALVE
FUEL PRESSURE
SENSOR
BOOST
SENSOR
CMP SENSOR
ECT
SENSOR ~I--_-I.
FUEL
CKP SENSOR
TEMPERATURE
SENSOR
EGRVALVE
POSITION
SENSOR PCM
BLOWER L--_----I
MOTOR
REFRIGERANT
PRESSURE ~ ~~~-~~~~~~~~~--------------I
SWITCH (LOW) VARIABLE SWIRL:
~)---t-o CONTROL ,
SOLENOID VALVE :
AlC
COMPRESSOR
AlC RELAY
AlC
:SWITCH
: THERMO SWITCH
,,
'- -- - - - - - - - - - - - - - WITH AlC- - - - - - - - - - - - - - --
DBG102BWBY02
01-408-6
-I:-+----{ E
DLC
r-------t-,--~~+_-----~~--------~IG-
FEN
KLN
TEN
F
DLC-2
KLN
L----ITEN
PCM
(BUILT INTO
GLOW INDICATOR
BARO SENSOR)
LIGHT ,..--+-----+---------(
VEHICLE
SPEED SIGNAL
FUEL
INJECTOR
FUEL
INJECTOR
NO.3
FUEL
INJECTOR
NO.2
FUEL
INJECTOR
IAT NO.1
SENSOR
NO.2
DBG102BWBY03
01-408-7
...,
RFWLOCK
SOLENOID \..
APP J---+-+-.z' VALVE
SENSOR
RFW FREE
SOLENOID
.J---+-.z' VALVE
FUEL PRESSURE
SENSOR
BOOST
SENSOR
CMP SENSOR
ECT
SENSOR L!:::I----{
FUEL CKPSENSOR
TEMPERATURE
SENSOR
EGRVALVE
POSITION
SENSOR PCM
IJ--+--o o--I--+-.... GLOW

BLOWER L...-_----'
PLUG
RELAY
MOTOR
EGR CONTROL
SOLENOID VALVE
REFRIGERANT
PRESSURE
~~-~~ o-~~~ CONTROL :
SOLENOID VALVE :
AlC ,
COMPRESSOR
AlC RELAY
AlC
!SWITCH
,, THERMO SWITCH
,,
'- - - - - - - - - - - - - - - • WITH AlC' - - - - - - - - - - - - - - -
DBG102BWBY02
01-408-8
ENGINE CONTROL SYSTEM BLOCK DIAGRAM [WL-C, WE-C]
dcf014000000t26
PCM
BATTERY
~
CPPSWITCH
~ IDLE SPEED CONTROL
NEUTRAL SWITCH
~
APP SENSOR I~ GLOW CONTROL FUEL METERING VALVE
IDLE SWITCH
~ BOOST PRESSURE
FUEL INJECTOR
MAF SENSORIIAT SENSOR NO.2 I~ CONTROL VBC SOLENOID VALVE
IAT SENSOR NO.1

~ FUEL INJECTION AMOUNT
CONTROL
EGR SOLENOID VALVE
ECT SENSOR
~ FUEL INJECTION TIMING
FUEL TEMPERATURE SENSOR

~ CONTROL INTAKE SHUTTER SOLENOID
VALVE
BAROSENSOR
~ MULTIPLE FUEL
INJECTION CONTROL
(HALF, FULL)
BOOST SENSOR
~ GLOW INDICATOR LIGHT
FUEL PRESSURE SENSOR
~ FUEL PRESSURE
CONTROL GLOW PLUG RELAY
CMPSENSOR
~ AlC RELAY
~
CKPSENSOR EGR CONTROL
IMMOBILIZER-RELATED
VEHICLE SPEED SIGNAL
~ AlC CUT-OFF CONTROL
INFORMATION
AlC SWITCH
~ MIL

~ IMMOBILIZER SYSTEM
IMMOBILIZER-RELATED
INFORMATION
DBG140BTBOO3
01-408-9
ENGINE CONTROL SYSTEM RELATION CHART [WL-C, WE-C]
dcf01400000Ot27
x: Applicable
e"E e"E e"E

0 0
e"E ()
"E
:J
0
()
Ol
()
c:
0 e"E E
e"E
*
c:
Item e"E 0
()
0
E
ell
·E
+='
U
Q) 0
()
>-
~ :~
c: c:
e"E
0 (/)
0
()
"0
Q)
:J
(/)
(/)
~ U
0 0
13Q)
Q)
.2
~
:J
(/)
(/)
e"E ()
:!=
0
a;
~
Q)
Co
0
() Co
Q)
:~ :~
Q)
a. ~
Co
0
() -5 :c0
(/)
"lii rr. ()
E
Q) ~ 0 Q) Q) +='
"S
Q)
~ a 0
(()
:J
LL
:J
LL :2
:J
LL
C!J
W ~ .E
Input device
Battery x
CPP switch x x x x x
Neutral switch x x x x x
APP sensor x x x x x x x x
Idle switch x x
MAF sensor/lAT sensor No.2 x x x x x
IAT sensor No.1 x x
ECT sensor x x x x x x x x x
Fuel temperature sensor x x x
BARO sensor x x x x x x
Boost sensor x
Fuel pressure sensor x x x
CMP sensor x x x x
CKP sensor x x x x x x x x x
Vehicle speed signal x x x x
AlC switch x
EGR valve position sensor x
Immobilizer-related information x
Output device
Fuel metering valve x x
Fuel injector x x x x x
VBC solenoid valve x
EGR solenoid valve x
EGR control solenoid valve x
Intake shutter solenoid valve (half,
x
full)
Glow indicator light x
Glow plug relay x
AlC relay x
Immobilizer-related information x
IDLE SPEED CONTROL OUTLINE [WL-C, WE-C]

dcf014000000t28
• The peM feedback controls the idle speed by calculating the fuel injection amount so that the idle speed is at
the target idle speed corresponding to the driving conditions .
. 01-408-10
IDLE SPEED CONTROL BLOCK DIAGRAM [WL-C, WE-C]
dcf014000000t29
CPP SWITCH
I .......
I
NEUTRAL SWITCH
I ....
....
I
AlCSWITCH I ....
...
I
APPSWITCH I _........
I
ECTSWITCH
I
I ....... PCM .....1
""I
FUEL INJECTOR
I
CKPSWITCH I ........
I
VEHICLE SPEED .......
SIGNAL
FUEL PRESSURE .......

SENSOR
DBG140BTB850
IDLE SPEED CONTROL OPERATION [WL-C, WE-C]

dcf01400000Ot30
Feedback Control
• If there is a difference between the target idle speed and the actual idle speed, the PCM controls the fuel
injection amount so that the actual idle speed corresponds to the target idle speed.
Target idle speed

No load: 720 rpm
AlC ON: 750 rpm
Engine Speed Control while Warming Up

• Controls engine speed based on the input signal from the engine coolant temperature sensor (below 0 °C {32
OF}) so that the engine speed while warming up corresponds to the target engine speed.
Engine speed while warming up control

720-1,000 rpm
Engine Speed Fluctuation Prevention Control for Each Cylinder

• The PCM detects the engine speed fluctuation while idling and corrects the fuel injection amount per each
cylinder. Due to this, the variance in fuel injection amount caused by ununiformity of the cylinders (such as fuel
injectors) and engine vibration while idling are reduced.
GLOW CONTROL OUTLINE [WL-C, WE-C]

dcf01400000Ot31
• Heating of the glow plug is controlled by the PCM through the glow plug relay to improve engine startability.
• Energization time to the glow plug is determined according to the engine coolant temperature and engine
starting conditions.
GLOW CONTROL BLOCK DIAGRAM [WL-C, WE-C]

dcf014000000t32
.......
I ECT SENSOR I
·1
I GLOW INDICATOR
PCM
I CMP SENSOR
I ........ LIGHT
I CKP SENSOR
I ....
... ~I GLOW PLUG RELAY
DBG140BTB851
01-408-11
,
GLOW CONTROL OPERATION [WL-C, WE-C]
dcf014000000t33
• The glow plug relay operates under the following conditions:

During preheating timer operation
- During engine cranking
- While outer glow is operating
Preheating Timer
• The PCM operates the glow plug relay for several seconds after the engine switch is turned to the ON position
according to the engine coolant temperature. The higher the engine coolant temperature, the shorter the period
of the timer operation.
• The glow indicator light illuminates during the preheating timer operation to inform the driver that the glow
system is operating.
Glow Continuation Timer

• The PCM operates the glow plug relay for 120 s (max.). after the engine has been started with the engine
coolant temperature lower than 32°C {89.6 OF}. When the engine coolant temperature reaches 32°C {89.6 OF}
or more, the glow continuation timer is cancelled.
BOOST PRESSURE CONTROL OUTLINE [WL-C, WE-C]

dcf01400000Ot34
• The PCM duty-controls the VBe solenoid valve.

• By changing the opening angle of the guide blades (variable vanes) around the turbine impellers according to
the engine driving conditions, turbocharger response, vehicle acceleration performance, and fuel consumption
have been improved in every driving range.
BOOST PRESSURE CONTROL BLOCK DIAGRAM [WL-C, WE-C]

dcf01400000Ot35
I BATTERY I ....
APP SENSOR
I
..
...
ECT SENSOR ......
BARO SENSOR
.... PCM ···~I VBC SOLENOID VALVE I
BOOST SENSOR ......
CKP SENSOR
..
~
DBG140BTB852
BOOST PRESSURE CONTROL OPERATION [WL-C, WE-C]

dcf01400000Ot36
• The VBC solenoid valve is controlled by the variable boost control signal (duty signal) from the PCM. The
longer the valve is ON, the higher the boost pressure becomes.
• The PCM performs feedback control by determining the period that the VBC solenoid valve is ON based on the
engine speed and the fuel injection amount so that the optimum boost pressure can be obtained.
• Under driving conditions where more boost pressure is needed, the PCM sends the variable boost control
signal to extend the ON period of the VBC solenoid valve, moving the guide blades in the turbocharger in the
closing direction.
• Under driving conditions where less boost pressure is needed, the PCM sends the variable boost control signal
to shorten the ON period of the VBC solenoid valve, moving the guide blades in the turbocharger in the
opening direction.
FUEL INJECTION AMOUNT CONTROL OUTLINE [WL-C, WE-C]

dcf01400000Ot37
• The fuel injection amount is controlled by the opening of the nozzle in the fuel injector based on the signal from
the PCM.
• The PCM corrects the variation in the fuel injection amount of each cylinder by inputting the fuel injector
calibration code (or fuel injector calibration bar code) into the PCM.
01-408-12
FUEL INJECTION AMOUNT CONTROL BLOCK DIAGRAM [WL-C, WE-C]
dcf01400000ot38
CPP SWITCH
I
J ......
NEUTRAL SWITCH
I .......
I
APP SENSOR I ........
I
......
I IDLE SWITCH
I
.......
MAF SENSOR/IAT
SENSOR NO.2 I
........
I IAT SENSOR NO.1
I
I ECT SENSOR
I ......
FUEL TEMPERATURE
SENSOR ......
PCM .....J
..... 1 FUEL INJECTOR
I
BARO SENSOR I ....
....
I
FUEL PRESSURE ...

SENSOR ~
CMP SENSOR
I ......
I
CKP SENSOR I ....
....
VEHICLE SPEED
SIGNAL ......
DBG140BTB853
FUEL INJECTION AMOUNT CONTROL OPERATION [WL-C, WE-C]

dcf01400000ot39
Basic Injection Amount

Operation
• Fuel injection amount is controlled based on the fuel injector nozzle opening period.
Injection amount calculation

• The PCM calculates the optimum fuel injection amount according to engine operation conditions.
• The following two amount values are compared and the one of less amount is selected for the final injection
amount.
Basic injection amount

.• The logically necessary injection amount is calculated based on the accelerator opening angle and engine
speed.
Maximum injection amount

• The maximum injection amount is calculated by correcting the basic injection amount based on driving
conditions such as mass air flow, intake air temperature, and barometric pressure, intake air temperature and
engine coolant temperature.
FUEL INJECTION TIMING CONTROL OUTLINE [WL-C, WE-C]

dcf01400000ot40
• The PCM determines and controls the optimum fuel injection timing according to engine operation conditions
based on the signals from each input sensor.
01-408-13
FUEL INJECTION TIMING CONTROL BLOCK DIAGRAM [WL-C, WE-C]
dcf01400000Ot41
CPP SWITCH
......
NEUTRAL SWITCH
I
I
.....
APP SENSOR I
I ......
MAF SENSOR/ I ...
JII""
IAT SENSOR NO.2
IAT SENSOR NO.1 I .....

I
I ..... PCM
.. I
111"""1 FUEL INJECTOR -I
ECT SENSOR
I
FUEL TEMPERATURE ....
SENSOR "..
BARO SENSOR
I
I .......
CMP SENSOR
I .....
I "..
CKP SENSOR
I
I .......
DBG140BTB854
FUEL INJECTION TIMING CONTROL OPERATION [WL-C, WE-C]

dcf01400000Ot42
• Fuel injection start timing is determined based on the fuel injection amount and crank angle signals input from
the crankshaft position sensor.
CRANK ANGLE BASIC POSITION TDC
CKP INPUT SIGNAL

FUEL INJECTION STARTS
INJECTION SIGNAL _ _ _ _ _ _ _ _ _ _ _ _ ---.JhL__~--i------~

I I
_ _ _ __
"I I"
.:1:1
PILOT INJECTION PERIOD 1 1I
CORRECTIO~
INJECTOR LIFT IL_ _---.ll I L -_ _ __
:~7' -: ~.
INTERVAL MAIN INJECTION TIMING
DBG140BTB860
Determination of Fuel Injection Timing

• The peM calculates the optimum fuel injection timing based on the predetermined target fuel injection timing
and input signals from each sensor.
Target Fuel Injection Timing

• Target fuel injection timing is calculated based on engine speed and fuel injection amount.
Injection Timing Correction

• Actual fuel injection timing is corrected based on the input signals from each sensor such as intake air
temperature, engine coolant temperature, and barometric pressure.
01-408-14
MULTIPLE FUEL INJECTION CONTROL OUTLINE [WL-C, WE-C]
dcf01400000ot43
• Pilot injection: To reduce noise and NOx, the peM performs multiple fuel injections before the main injection
according to the vehicle driving conditions.
MULTIPLE FUEL INJECTION CONTROL BLOCK DIAGRAM [WL-C, WE-C]

dcf01400000ot44
CPP SWITCH
I .......
I
NEUTRAL SWITCH I ......
I
APP SENSOR I
I
......
MAF SENSOR/IAT I .......
SENSOR NO.2 I PCM
....
.... FUEL INJECTOR
ECT SENSOR
I ......
J
BARO SENSOR I ....
....
I
CMP SENSOR I
I ......
CKP SENSOR I .......
I
DBG140BTB855
MULTIPLE FUEL INJECTION CONTROL OPERATION [WL-C, WE-C]

dcf01400000ot45
Function
• In single injection, ignition delay becomes longer and much fuel is injected before ignition since the ignition has
started. Therefore, the fuel is combusted rapidly at a high temperature and a high pressure, resulting in
increased noise and NOx.
• To prevent this, the peM performs multiple fuel injection. Due to this, the fuel is combusted slowly and the
occurrence of noise and NOx is suppressed.
SINGLE INJECTION MULTIPLE INJECTION
INJECTION PATTERN INJECTION PATTERN
FUEL INJECTION DELAY FUEL INJECTION DELAY
CRANK ANGLE CRANK ANGLE ..L-_-'--------'L-----'-

TOC TPC
DBG140BTB861
Operation
• Injection patterns of the multistage injection control according to the combination of injection times are shown in .
the figure. The peM selects the optimum injection pattern based on the vehicle conditions and performs
injection for 3 times at maximum.
• While in a driving condition at low engine speed and low engine load, the fuel injection time is increased up to 3
times to reduce knocking noise which occurs during combustion.
• While in a driving condition at high engine speed and high engine load, the fuel injection time is reduced to one
time at minimum to improve output and fuel economy.
01-408-15
,
-BASIC CRANK ANGLE TOC
r:\
CKPSIGNAL
n n n
PILOT INJECTION PILOT INJECTION MAIN INJECTION
3-STAGE
INJECTION - T - - - - - - - - - ' L-__--J: L--_ _ _ _ _ _ _ _ _ _ _ _ __
----'nL______________
PILOT INJECTION : MAIN INJECTION
2-STAGE _________ ---JnL-_______

INJECTION
---lnL______________
I
: MAIN INJECTION
SINGLE ___________________
INJECTION :
I
I
DBG140BTB862
Operation condition
• The PCM determines the number of times fuel injection occurs based on the engine speed, fuel injection
amount, and signals from each sensor.
• When the engine is started, the PCM calculates the number of times fuel injection occurs based on the engine
coolant temperature, engine speed and fuel injection amount.
FUEL PRESSURE CONTROL OUTLINE [WL-C, WE-C]

dcf01400000ot46
• The PCM performs the feedback control of the fuel pressure in the common rail to gain optimum fuel injection
pressure according to engine operation conditions.
• Because the fuel pressure can be controlled regardless of engine operation conditions, high pressure fuel
injection even with low engine speed is possible. Due to this, generation of NOx and particulate matter can be
reduced.
FUEL PRESSURE CONTROL BLOCK DIAGRAM [WL-C, WE-C]

dcf01400000ot47
APP SENSOR I ....

...
I
MAF SENSOR/IAT
SENSOR NO.2
I .....
.....
I
I
ECTSENSOR
I
FUEL TEMPERATURE I ..... PCM
....
SENSOR
I -JIll" FUEL METERING VALVE
BAROSENSOR
I
I ....
FUEL PRESSURE
SENSOR
I
I
.....
CKPSENSOR I
.....
DBG140BTB856
FUEL PRESSURE CONTROL OPERATION [WL-C, WE-C]

dcf01400000ot48
• The PCM calculates the target fuel pressure based on the engine speed and fuel injection amount.
• The PCM operates the fuel metering valve which is installed to the supply pump to adjust the fuel pressure in
the common rail to the target fuel pressure.
• By controlling the amount of pumped fuel from the supply pump with the fuel metering valve, the fuel pressure
in the common rail is controlled and a constant, optimum injection pressure has been realized.
01-408-16
EGR CONTROL OUTLINE [WL-C, WE-C]
dcf014000000t49
• The PCM controls duty-cycle type solenoid valves and an ON/OFF type solenoid valve to control the EGR
valve in order to obtain the optimum EGR amount for the actual engine operating condition. Due to this,
emission performance and driveability has been improved.
• When introducing the exhaust gas during low engine speed, the PCM controls the intake shutter solenoid valve
(half) to control the intake shutter valve opening angle. Thus the exhaust gas is channelled into the combustion
chamber efficiently. Due to this, emission performance and driveability has been improved. (WE-C)
• As the MAF sensor deteriorates and an error margin is created between the target and the actual intake air
amount, the PCM conducts learning and correction.
EGR CONTROL BLOCK DIAGRAM [WL-C, WE-C]

dcf01400000Ot50
CPP SWITCH I .......

I
NEUTRAL SWITCH I ........
I
APP SENSOR I ........
I
.......
I IDLE SWITCH
I ....... EGR SOLENOID
VALVE
.......
MAF SENSOR/IAT
SENSOR NO.2
....... .......
I ECT SENSOR
II EGRCONTROL
SOLENOID VALVE
BAROSENSOR I ....... PCM
INTAKE SHUTTER
FUEL PRESSURE ...... ....... SOLENOID VALVE
SENSOR (HALF)
CKP SENSOR I
I ...... ....... INTAKE SHUTTER
SOLENOID VALVE
(FULL)
VEHICLE SPEED
SIGNAL
.......
EGRVALVE ......
POSITION SENSOR
DBG140BTB857
EGR CONTROL OPERATION [WL-C, WE-C]

dcf01400000ot51
EGR Valve Operation

• To improve emission performance, target EGR valve position is decided based on intake air flow, engine
speed, engine coolant temperature and fuel injection amount.
• The flow amount of the EGR is calculated from the difference between the following amounts.
- Target intake air amount that is mainly calculated from engine speed and fuel injection amount
- Actual intake air amount that is mainly detected by MAF sensor/IAT sensor No.2
• The PCM controls the vacuum applied to the EGR valve by opening and closing a two-duty solenoid valve.
Intake Shutter Valve Operation

Close condition
• The PCM turns on the intake shutter solenoid valve (half) and the intake shutter solenoid valve (full) in order to
close the intake shutter valve when the engine switch is at OFF.
01-408-17
Halfway open condition (WE-C)
• The PCM turns the intake shutter solenoid valve (half) on when all of the following conditions are met.
Engine coolant temperature is above threshold level.
Intake air temperature is threshold level.
Barometric pressure is above threshold level.
Engine speed is below threshold level.
Vehicle speed is below threshold level.
Fuel injection amount is below threshold level.
Full open condition

• For conditions other than closed and halfway open, the PCM turns off the intake shutter solenoid valve (half)
and the intake shutter solenoid valve (full) in order to open the intake shutter valve.
MAF Learning
• After learning is initiated, the PCM calculates the actual intake air amount for the complete learning period.
• The PCM calculates the deviation between the target and actual intake air amount, then, based on the
deviation, derives the learning factor. The PCM stores the learning factor and uses it to correct the intake air
amount. Due to this, the error margin of the MAF sensor is resolved. If the deviation factor is less than the
specified amount, the PCM does not calculate nor update the learning factor.
• The PCM stores the learning factor until the next time the factor is updated. The factor is erased using the
M-MDS.
Using the M-MDS for learning

• By using the M-MDS, the learning function can be freely controlled. Due to this, even if the PCM or MAF
sensor/lAT sensor No.2 is replaced, the learning factor can be stored again.
• When using the M-MDS to control the MAF learning function, learning is performed at the following three
engine speed levels.
720 rpm
- 1,850 rpm
- 2,500 rpm
Without using the M-MDS for learning

• By shorting circuit the DLC terminal TEN five times within 5 s, the learning function can be freely controlled.
Due to this, even if the PCM or MAF sensor/lAT sensor No.2 is replaced, the learning factor can be stored
again.
• The glow indicator light illuminates while MAF learning is performed, and flashes five times after it is
completed.
AlC CUT-OFF CONTROL OUTLINE [WL-C, WE-C]

dcf01400000ot52
• The AlC relay is turned on and off according to engine operation conditions to improve drivability.
AlC CUT-OFF CONTROL BLOCK DIAGRAM [WL-C, WE-C]

dcf01400000ot53
....
I APP SENSOR I
I .....
....
I ECT SENSOR I
I ...
.... PCM
~I AlC RELAY
I I ....
_
VSS
I CKP SENSOR
I ~
DBG140BTB858
AlC CUT-OFF CONTROL OPERATION [WL-C, WE-C]

dcf01400000ot54
• When the accelerator opening angle is 87.5 % or more, the PCM cuts the power supply to the A/C relay for 3 s.
• When the engine coolant temperature is 113°C {235 OF} or more, the PCM turns off the power supply to the AI
C relay until the engine coolant temperature is less than 110°C {230 OF}.
01-408-18
IMMOBILIZER SYSTEM OUTLINE [WL-C, WE-C]
dcf01400000Ot55
• While the immobilizer system is operating, the PCM cuts off fuel delivery and stops pressure feeding fuel to the
common rail.
IMMOBILIZER SYSTEM BLOCK DIAGRAM [WL-C, WE-C]

dcf01400000ot56
I-----I~ FUEL METERING VALVE
IMMOBILIZER-
RELATED PCM
FUEL INJECTOR
INFORMATION
IMMOBILIZER-
RELATED
INFORMATION
DBG140BTBB59
IMMOBILIZER SYSTEM OPERATION [WL-C, WE-C]

dcf01400000ot57
• When the immobilizer system is activated, the following controls are carried out.
Fuel injector: OFF (Set fuel quantity to zero.)
- Fuel metering valve: ON (Set minimum common rail pressure.)
PCM FUNCTION [WL-C, WE-C]

dcf01401 BBBOto3
Function Table
• Control descriptions are as follows:
Function Contents
Idle speed control Performs feedback control of idle speed by calculating fuel injection amount so that idle speed
is at target idle speed corresponding to driving conditions.
Glow control Controls glow plug operation time via glow plug relay to improve engine startability.
Boost pressure control Controls turbocharger guide blade angle according to engine operation conditions to improve
turbocharger response, acceleration performance, and fuel economy.
Fuel injection amount control Performs optimum fuel injection according to engine operation conditions by controlling signals
to open/close fuel injector nozzle.
Fuel injection timing control Controls optimum fuel injection timing according to engine operation conditions.
Multiple fuel injection control Performs multiple fuel injection according to engine operation conditions to reduce noise and
NOx.
Fuel pressure control Adjusts to optimum fuel pressure according to engine operation conditions.
Intake shutter valve control Adjusts intake shutter valve to optimum opening angle according to engine operation
conditions.
EGR control Controls EGR valve so that EGR volume is optimized according to engine operation conditions.
AlC cut-off control Controls operation of AlC according to engine operation conditions to assure drivability.
Immobilizer system Inhibits engine starting by cutting fuel injection and pressure feeding fuel to common rail when
immobilizer system is activated.
PCM CONSTRUCTION [WL-C, WE-C]

dcf01401 BBBOto4
• A 154-pin (two block) PCM connector has been adopted.
• The PCM has a built into piezoelectric element BARO sensor.
01-408-19
MASS AIR FLOW (MAF) SENSOR FUNCTION [WL-C, WE-C]
dcf014013215to3
• Detects the intake air amount (mass airflow amount).
MASS AIR FLOW (MAF) SENSOR CONSTRUCTION/OPERATION [WL-C, WE-C] ( ..

dcf014013215to4
• Installed to the air cleaner.

• With built-in IAT sensor No.2
• Converts the mass intake airflow amount to voltage.
• When the temperature of the metal decreases, the resistance decreases. Using this characteristic, the hot wire
captures heat from the flow of intake air and converts the intake airflow amount to voltage.
• The cold wire converts intake air density to voltage from the ambient temperature of the cold wire, using the
characteristic of air whereby the intake air density decreases due to the increase in intake air temperature.
• The voltages obtained by the hot wire (intake
airflow amount) and the cold wire are compared MAF
SENSOR
and the electric potential becomes stable by
supplying the difference in voltage to the
transistor. The voltage supplied to the hot wire is
output as the mass intake airflow amount.
HOT WIRE
INTAKE AIR
DBG140ATB303
MAF SENSOR CHARACTERISTIC (REFERENCE)

(V)
5
HOTWIRE
4
v
PCM
MAF SENSOR V
V
......... v~
FIXED RESISTANCE
01 2 5 10 20 50 100 200 (g/8)

MASS AIRFLOW AMOUNT
DBG140ATB304
01-408-20
INTAKE AIR TEMPERATURE (IAT) SENSOR NO.2 FUNCTION [WL-C, WE-C]
dcf014018842to5
• Detects the intake air temperature, and sends it to the PCM as an intake air temperature signal.
INTAKE AIR TEMPERATURE (IAT) SENSOR NO.2 CONSTRUCTION/OPERATION [WL-C, WE-C]

• Installed to the air cleaner.
• Built into the mass airflow sensor.
• The thermistor type IAT sensor No.2 changes
resistance according to the intake air
temperature.
• The resistance decreases if the intake air
temperature increases and, conversely,
increases if the intake air temperature decreases. MAF SENSOR
IAT SENSOR NO.2
IAT SENSOR NO.2 CHARACTERISTIC (REFERENCE)

30
20
~
!~ 13.6-18.4
PCM
10 ~ KILOHM
IAT SENSOR NO.2

~ 7
I I\.'\.
0 5 I'\.'\.'\.
-l
g 3 "&.
w ~~ 2.21-2.69
0 2 KILOHM
z
~
(f)
~ ~
1i:i 0.7
w 0.493 0.667
a: 0.5
KILOHM
I I
I",
~
0.3
0.2 -20 0 20 40 60 80
{-4} {32} {68} {104} {140} {176}
INTAKE AIR TEMPERATURE (OC ("F})
DBG140ATB306
INTAKE AIR TEMPERATURE (IAT) SENSOR NO.1 FUNCTION [WL-C, WE-C]

dcf014018842to7
• The IAT sensor No.1 detects the intake air temperature which has passed through the charge air cooler, and
sends it to the PCM as an intake air temperature signal.
01-408-21
..,
INTAKE AIR TEMPERATURE (IAT) SENSOR NO.1 CONSTRUCTION/OPERATION [WL-C, WE-C]
dcf014018842t08
• Built into the boost sensor.

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

18
PCM 16
T
IAT SENSOR NO.1 ,?14
.J::
012
:2
CPU ~10
~ 8
~
~ 6
(f)
ffi 4
rr.
2
~ 0_
20 -10 0 10 20 30 40 50 60 70 80
{-4} {14} {32} {50} {68} {86} {104}{122}{140}{158}{176}
INTAKE AIR TEMPERATURE (OC {OF} )
DBG140BTB302
BOOST SENSOR FUNCTION [WL-C, WE-C]

dcf014018212t03 •
• The boost sensor detects the intake air pressure as an absolute pressure, and sends it to the peM as an intake
air pressure signal.
BOOST SENSOR CONSTRUCTION/OPERATION [WL-C, WE-C]

dcf014018212t04
• The boost sensor is installed to the intake manifold.

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

DBG140BTB301
01-408-22
ACCELERATOR PEDAL POSITION (APP) SENSOR FUNCTION [WL-C, WE-C]
dcf014041609t03
• The APP sensor is installed on the accelerator pedal, and detects how much the accelerator pedal is being
depressed from the change in the resistance value (variable resistance).
ACCELERATOR POSITION
ACCELERATOR POSITION SIGNAL (MAIN)
EXTERNAL VIEW SIGNAL (MONITOR)
GROUND
DBG140ATB459
ACCELERATOR PEDAL POSITION (APP) SENSOR DESCRIPTION [WL-C, WE-C]

dcf014041609t04
• The APP sensor is a potentiometer type and works is the same way as the throttle position sensor.
• The APP sensor contains two circuits for detecting accelerator position: main circuit and monitor circuit. The
main circuit is used for the controls operated by the PCM (e.g. fuel injection amount control). The monitor circuit
is used for detecting malfunctions in the APP sensor.
• When voltage difference between the main and monitor circuits increases, the PCM determines that the APP
sensor is malfunctioning and stores DTC. Thus, a detection condition item has been added to DTC.
• The input voltage characteristic of the APP sensor is as shown.
APP SENSOR CHARACTERISTIC (REFERENCE)

APP SENSOR PCM
(V)
W 3.4-3.8
Cl
~
:..J
~
I-
:::>
~ 0.4-0.8
NOT
ACCELERATED
ACCELERATOR
CLOSE . - PEDAL POSITION - OPEN
DBG140BTB307
IDLE SWITCH FUNCTION [WL-C, WE-C]

dcf01406647ot03
• The idle switch is mounted to the accelerator pedal and inputs to the PCM whether the accelerator pedal is
depressed or released. The PCM detects the idle switch signal as an idle signal.
• The idle signal inputted to the PCM is compared with the accelerator opening signal detected from the APP
sensor, and on-board diagnostic of the idle switch and the APP sensor is performed.
IDLE SWITCH
DBG140ATB002
01-408-23
IDLE SWITCH DESCRIPTION [WL-C, WE-C]
dcf01406647Ot04
• When the push rod is pushed in (the accelerator pedal is released) a preset amount, the contact of the idle
switch closes, and the PCM determines that the engine is idling. When the contact of the idle switch is open
(OFF), the PCM determines that the engine is not idling. (.
IDLE SWITCH
,
OFF--i_ON
,,
,,
,-'
I
'-
DBG140ATB455
FUEL TEMPERATURE SENSOR FUNCTION [WL-C, WE-C]

dcf014018843t03
• The fuel temperature sensor detects fluctuations in resistance of the thermistor to detect the fuel temperature
which is necessary for the fuel injection amount correction.
FUEL TEMPERATURE SENSOR CONSTRUCTION/OPERATION [WL-C, WE-C]

dcf014018843t04
• Installed to the supply pump.

• The thermistor type fuel temperature sensor changes resistance according to the fuel temperature.
• The resistance decreases if the fuel temperature increases and, conversely, increases if the fuel temperature
decreases.
I~(
THERMISTOR
FUEL TEMPERATURE SENSOR CHARACTERISTIC (REFERENCE)

PCM
~
I
g
g
w
()
z
~
CJ)
Ci5
~ L-__________~==:=========~
FUEL TEMPERATURE (OC {OF})
DBG140BTB308
FUEL PRESSURE SENSOR FUNCTION [WL-C, WE-C]

dcf014018213t01
• Measures the fuel pressure in the common rail.

• Measured fuel pressure is used for the fuel pressure control.
01-408-24
FUEL PRESSURE SENSOR CONSTRUCTION/OPERATION [WL-C, WE-C]
dcf014018213to2
• Installed on the common rail.
COMMON RAIL FUEL PRESSURE SENSOR
• Converts the fuel pressure in the common rail to a FUEL PRESSURE SENSOR CHARACTERISTIC (REFERENCE)
voltage signal and outputs it to the PCM. 5.0
..,../ -
~ 4.0 v
~ 3.0
V
..,../
~
:..J 20
•
V
~ 1.0 V
./
0.00 40 BO 120 160 200

{O,O} {4.1, {B.2, {12.2, {16.3, {2.0,
5,B01} 11,603} 17,404} 23,206} 29,007}
FUEL PRESSURE (MPa {kgf/m2, psi})
D8G 1408T8304
ENGINE COOLANT TEMPERATURE (ECT) SENSOR FUNCTION [WL-C, WE-C]

dcf014018841to3
• The ECT sensor detects the engine coolant temperature.
ENGINE COOLANT TEMPERATURE (ECT) SENSOR CONSTRUCTION/OPERATION [WL-C, WE-C]

dcf014018841t04
• The ECT sensor is thermistor type, and is installed in the cylinder head.
• The ECT sensor inputs the thermistor resistance, ~~=;:;;---===:::::--E-C-T-S-EN-S-O-R-C-H-A-R-A-C-T-ER-I-ST-I-C-'
which changes according to the engine coolant (REFERENCE)
temperature, to the PCM as a voltage. I t
s:!w
IO
Z
~
en
1i5
w
sa:
g~L--_____
.-..
ECT SENSOR LOW HIGH
ENGINE COOLANT TEMPERATURE
D8G140AT8302
CAMSHAFT POSITION (CMP) SENSOR FUNCTION [WL-C, WE-C]

dcf014018230to1
• The CMP sensor detects pulse wheel of intake camshaft pulley rotational signals as cam angle signals.
\
01-408-25
CAMSHAFT POSITION (CMP) SENSOR CONSTRUCTION/OPERATION [WL-C, WE-C]
dcf01401823ot02
• The CMP sensor is installed on the cylinder head on the front side of engine.
• The CMP sensor consists of a Hall element with a magnetic sensor, and a processing circuit that performs
signal amplification and identification.
• CMP sensor is a hall-element type and it detects hall voltage generated by the change in magnetic flux of the
magnet inside the sensor and hall element as the camshaft angle signal.
• One pulse are detected per one rotation of the camshaft by the projections on the intake camshaft pulley.
• If the CMP sensor is removed/installed or replaced, magnetized objects such as metal shavings adhering to the
sensor could cause fluctuation in the magnetic flux of the magneto resistance element, causing abnormal
sensor output which could adversely affect engine control.
PCM
CMP SENSOR
CMP
SENSOR __+---------~---+~
OUTPUT
SIGNAL
PULSE WHEEL
en
INTAKE CAMSHAFT
~ ~
II
~
I
~
0
PULLEY 26 0 334
DBG140BTB312
CRANKSHAFT POSITION (CKP) SENSOR FUNCTION [WL-C, WE-C]

dcfO 1401822ot03
• The CKP sensor detects pulse wheel rotational signals as crank angle signals.
. "')
01-408-26
CRANKSHAFT POSITION (CKP) SENSOR CONSTRUCTION/OPERATION [WL-C, WE-C]
dcf01401822Ot04
• The CKP sensor is installed to the clutch housing.

• The pulse wheel which is installed to the dual-mass flywheel has 58 projections and spaces with 6° of crank
angle between each projection.
• The fluctuation in magnetic flux density detected by the magnetic pickup coil in the crankshaft position s'ensor
is input to the PCM as a sensor output signal.
• If the crankshaft position sensor is removed/installed or replaced, magnetized objects such as metal shavings
adhering to the sensor could cause fluctuation in the magnetic flux of the magnetic pickup coil, causing
abnormal sensor output which could adversely affect engine control.
FLYWHEEL
DBG140BTB313
EGR VALVE POSITION SENSOR FUNCTION [WL-C, WE-C]

dcf01402030Ot02
• The EGR valve position sensor measures EGR valve lift amount and sends signal to the PCM, allowing the
PCM to diagnose a EGR system malfunction when there is a discrepancy between target and actual opening
angles of the EGR valve.

CHARACTERISTIC (REFERENCE)
EGR VALVE POSITION SENSOR ~ (Umin.)

~ 1,020-1,220 .... --------------
5
....I
LL
EGRVALVE §
~
30.0-36.6 -i :
~ -60.0 -i------i----------
0.54
DBG140ATB311
CLUTCH PEDAL POSITION (CPP) SWITCH FUNCTION [WL-C, WE-C]

dcf014018660to3
• The CPP switch detects the clutch connection condition.
01-408-27
CLUTCH PEDAL POSITION (CPP) SWITCH DESCRIPTION [WL-C, WE-C]
dcf01401866Ot04
• The CPP switch is mounted to the top of the clutch pedal. When the clutch pedal is depressed, the contact of
the CPP switch closes (ON) and the PCM detects below 1.0V. When the clutch pedal is released, the contact
opens (OFF) and the PCM detects B+.
RELEASED (SWITCH OFF) PCM
t
r
ON -:~OFF CPPSWITCH
t
I
I
;
I
~
I
I
~~ ~
I
CPU
PUSH ROD
DEPRESSED (SWITCH ON)
DBG140BTB550
NEUTRAL SWITCH FUNCTION [WL-C, WE-C]

dcf01401764Ot03
• Detects shift lever neutral position.
NEUTRAL SWITCH CONSTRUCTION/OPERATION [WL-C, WE-C]

dcf01401764Ot04
• While the shift lever is in the neutral position, the contact point closes (ON) and the PCM detects below 1.0 V.
While the shift lever is not in the neutral position, the contact point opens (OFF) and the PCM detects B+.
NEUTRAL SWITCH
NOT IN NEUTRAL (SWITCH OFF) PCM
t
~ NEUTRAL (SWITCH ON)
t
PUSH ON
DBG140BTB305
01-408-28
SUSPENSION
OUTLINE ................. 02-00 FRONT SUSPENSION ....... 02-13

WHEEL ALIGNMENT ....... 02-11 REAR SUSPENSION ........ 02-14
WHEEL AND TIRES ........ 02-12
02-00 OUTLINE
SUSPENSION ABBREVIATIONS . ..... 02-00-1 SUSPENSION SPECIFICATIONS ..... . 02-00-2
SUSPENSION FEATURES . .......... 02-00-1
SUSPENSION ABBREVIATIONS
dcf02000000Ot01
14X2 14-Wheel 2-Drive

4x4 4-Wheel 4-Drive
SUSPENSION FEATURES
dcf02000000Ot02
Improved driveability • Double wishbone suspension with torsion bar spring (front) has been adopted
Improved riding comfort • Parallel arranged lower arm and tie rod (4x2 models)
• Bias mount shock absorber (rear)
Improved serviceability • Vehicle height adjustment by anchor bolt
Precision wheel alignment • Camber and caster adjustment by shims
02-00-1
OUTLINE
SUSPENSION SPECIFICATIONS[Australian Specs.]

id020000100304
SPECIFICATIONS
Suspension
Item 4x2 4x4
Front suspension
Suspension Type Double wishbone
Spring type Torsion bar spring
Type Torsion bar
Stabilizer Except Hi-Rider: 27 {1.06}
Diameter (mm {in}) 28 {0.94}
Hi-Rider: 28 {0.94}
Shock absorber type Cylindrical, double-acting
Except Hi-Rider: 33°00'-37°00'
Inner 31 °30'-35°30'
Maximum Hi-Rider:31 °30'-35°30'
steering angle Except Hi-Rider: 30°00'-35°00'
Outer 27°00'-32°00'
Hi-Rider:27°00'-32°00'
Total toe-in (mm {in}) 2-8 {0.08-0.31} 3-9 {0.12-0.35}
Regular cab: 0°35' ±1 °
Regular cab and Stretch cab (with
Front wheel Hi-Rider (Stretch cab (with Rear
Camber angle Rear Access System): 0°44' ±1 °
alignment Access System)): 0°44' ±1 °
Double cab: 0°45' ±1 °
(·Unloaded Hi-Rider (Double cab): 0°45' ±1°
condition) Regular cab: 1°56'±1 °
Hi-Rider (Stretch cab (with Rear
Caster angle Rear Access System): 2°07'±1 °
Access System)): 2°07'±1 °
Double cab: 2°06'±1°
Hi-Rider (Double cab): 2°06' ±1°
Regular cab: 8°25'
Hi-Rider (Stretch cab (with Rear
Steering axis inclination Rear Access System): 10°37'
Access System)): 10°37'
Double cab: 10°35'
Hi-Rider (Double cab)): 10°35'
Rear suspension
Suspension Type Leaf spring
Spring type Semi elliptic leaf spring
Shock absorber type Cylindrical, double-acting
* : Fuel tank full; engine coolant and engine oil at specified level, and spare tire, jack, and tools in designated
position.
Wheel and tires

Item Specification
Size 15 x 61/2J I 15x61/2J I 16 x 7J
Wheel
Offset (mm {in}) 20 {0.79} I25 {0.98} I 10 {0.39}
Pitch circle diameter (mm {in}) 139.7 {5.500}
Material Steel IAluminum alloy I Steel I Aluminum alloy
Tire Size 215/70R15C 106/104S I
235175R15 109S I 245/70R16 111 S
'. ~
02-00-2
WHEEL ALIGNMENT
02-11 WHEEL ALIGNMENT

FRONT WHEEL ALIGNMENT
DESCRiPTION ................... 02-11-1
FRONT WHEEL ALIGNMENT DESCRIPTION

dcf0211 00000101
CAMBER AND CASTER
THE CAMBER ANGLE DECREASES IF

THE SHIM THICKNESS IS INCREASED
.--~~~
DO NOT USE MORE THAN ONE
THE CASTER ANGLE - - - - - - - " 1

DO NOT USE MORE THAN TWO
DECREASES IF THE SHIM
THICKNESS IS INCREASED
FRONT\::)
THE CASTER ANGLE INCREASES IF
THE SHIM THICKNESS IS INCREASED
DBG211ZTB001
• To adjust the camber and caster angles, loosen the bolts of the upper arm shaft and insert or remove the
adjustment shims .
• The amount of change of the camber and caster due to a 1 mm {0.039 in} shim increase or decrease is as
follows:
Camber: 1 mm {0.039 in} shim = 15'

=
Caster: 1 mm {0.039 in} shim 30'
02-11-1
WHEEL ALIGNMENT
Shim
Thickness (mm {in})
1.0 {0.039}
1.6 {0.063}
For camber
2.0 {0.079}
adjustment
3.2 {0.126}
4.0 {0.1S7}
1.0 {0.039}
1.6 {0.063}
For caster 2.0 {0.079}
adjustment 3.2 {0.126}
4.0 {0.1S7}
0.6 {0.024}
MAXIMUM STEERING ANGLE
4x2 (EXCEPT Hi-Rider) Hi-Rider, 4x4
DCF213ZTB001
• The maximum steering angle can be adjusted by turning the adjusting bolts.
TOTAL TOE-IN
• The total toe-in can be adjusted by turning the tie
rods.
• The left and right tie rods are both right
threaded.To increase the toe-in, turn the right tie
rod toward the front of the vehicle, and turn the
left tie rod by the same amount toward the rear.
• One turn of the tie rod (both sides) changes the
toe-in by about 30 mm {1.18 in}.
: : "
02-11-2
WHEEL AND TIRES
02-12 WHEEL AND TIRES

WHEEL AND TIRES OUTLINE . ....... 02-12-1 WHEEL AND TIRES
STRUCTURAL VIEW . ............. . 02-12-1
WHEEL AND TIRES OUTLINE

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

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

FRONT SUSPENSION OUTLINE ...... 02-13-1 FRONT LOWER ARM AND TIE ROD
FRONT SUSPENSION CONSTRUCTION
STRUCTURAL VIEW .. ............ 02-13-1 [4x2 (EXCEPT Hi-Rider)] .......... . 02-13-3
FRONT SUSPENSION DESCRIPTION .. 02-13-3
FRONT SUSPENSION OUTLINE

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

4x2 (Except Hi-Rider)
dcf02130000Qt02 liD
FRONT SHOCK ABSORBER
UPPER ARM
FRONT STABILZIER
LOWER ARM
DBG213ZTB001
02-13-1
FRONT SUSPENSION
Hi-Rider
UPPER ARM
FRONT STABILIZER
LOWER ARM
DBG213ZTB002
4x4
TORSION BAR SPRING
LOWER ARM
DBG213ZTB003
02-13-2
FRONT SUSPENSION
FRONT SUSPENSION DESCRIPTION
dcf02130000Ot03
• The vehicle height can be adjusted by turning the torsion bar spring anchor bolt. When adjustment is required,
adjust the vehicle height as follows:
1. Place the vehicle on level ground.
2. Inspect the front and rear tire pressure and adjust it if necessary.
3. Measure the distance form the center of each front wheel to the fender brim. -.
4x2 (Except Hi-Rider): 416-456 mm {16.4-17.9 in}
Hi-Rider: 512-552 mm {20.2-21.7 in}
4x4 (Stretch cab (with Rear Access Systetm)): 512-552 mm {20.2-21.7 in}
4x4 (Double cab): 502-542 mm {19.8-21.3 in}
*Difference between left and right: 10 mm {0.39in} max.
4. If the difference between left and right is not within the specification, adjust the vehicle height by turning the
torsion bar spring anchor bolt.
VEHICLE HEIGHT
4x2 4x4
ANCHOR BOLT
DBG213ZTB004
FRONT LOWER ARM AND TIE ROD CONSTRUCTION [4x2 (EXCEPT Hi-Rider)]
dcf02130000Ot04
• To prevent shimmy, the lower arm and tie rod are arranged in parallel.
THE ROD FORCE.

r;-::..
I
~.>==== - - - -----
II
II
II
r- ... >==--------- I
I
I
I
I
I
~:
LOWER ARM ,_..,,1
DBG213ZTB005
• By aligning the lower arm and tie rod in parallel, a change in toe-in, which is the cause of shimmy, does not
occur.
• The theory of why the tor-in change does not occur is that when force is applied to the tires form the front, they
move backward, thus resulting in the rectangle (formed by the links) becoming a parallelogram configuration.
As a result, the tires move in parallel to the inside and, although there is a slight change in the vehicle tread
width, there is no change in tor-in.
02-13-3
REAR SUSPENSION
02-14 REAR SUSPENSION

REAR SUSPENSION OUTLINE ....... 02-14-1 REAR SUSPENSION
STRUCTURAL ViEW ............... 02-14-1
REAR SUSPENSION OUTLINE

dcf021400000to1
• The rigid axle suspension with leaf spring is used for the rear suspension.
• To prevent wind-up of the leaf springs during rapid acceleration or deceleration, the shock absorber on the right
side is mounted at the rear of the axle and the left one is mounted at the front of the axle, (bias mount).ln order
to increase the rigidity in the lateral direction, wide shackle plates are used in the frame mounting.
• For Hi-Rider and 4x4 models, the rear springs are mounted on top of the axle housing to raise the center of
gravity. Thus, the shock absorbers attach directly to brackets welded to the axle housing.
REAR SUSPENSION STRUCTURAL VIEW

dcf02140000Ot02
4x2 EXCEPT
Hi-Rider
Hi-Rider, 4x4
DCF214ZTB001
02-14-1
DRIVELINE/AXLE
OUTLINE .... ............ . 03-00 DRIVE SHAFT .............. 03-13

ON-BOARD DIAGNOSTIC .... 03-02 DIFFERENTIAL. ............ 03-14
FRONT AXLE .............. 03-11 TRANSFER ................ 03-16
REAR AXLE ............... 03-12 4-WHEEL DRIVE ........... 03-18
03-00 OUTLINE
DRIVELINEIAXLE ABBREVIATIONS . .. 03-00-1 DRIVELINEIAXLE SPECIFICATIONS . . . 03-00-2
DRIVELINE/AXLE FEATURES . ....... 03-00-1
DRIVELINEIAXLE ABBREVIATIONS
dcf030000000t01

API American Petroleum Institute
DLC-2 Data Link Connector-2
DTC Diagnostic Trouble Code
LSD Limited Slip Differential
OFF Switch Off
ON Switch On
PCM Powertrain Control Module
RFW Remote Freewheel
SAE Society of Automotive Engineers
4x2 4-Wheel 2-Drive
4x4 4-Wheel 4-Drive
DRIVELINE/AXLE FEATURES
dcf03000000Qt02
Improved rigidity, reduced noise • Constant velocity joint type rear drive shaft adopted
and vibration • 2-part, 3-joint type propeller shaft with a center bearing support has been adopted (4x2,
4x4 rear)
• 1-part type propeller shaft has been adapted (4x4 front)
• Double offset-shaped constant velocity joint adopted for differential-side joint of front
drive shaft
• Bell-shaped constant velocity joint adopted for wheel-side joint of front drive shaft
Improved durability • Unit-design taper roller bearing has been adopted
Improved reliability • A spring-tensioned clip-type method of fixing the universal joint has been adopted (4x2,
4x4 rear)
• A direct control type transfer shift lever adopted
Improved operability • Remote freewheel (RFW) has been adopted
• Electronic control type transfer case adopted
Improved serviceability • Unit-design taper roller bearing has been adopted
Improved driveability • LSD has been adopted
03-00-1
OUTLINE
DRIVELINE/AXLE SPECIFICATIONS
dcf03000000Ot03
Item Specification
.,
Engine WL-3 WL-C I WE-C (.'
Transmission type R15M-D S15M-D S15MX-D
Vehicle type 4x2 4x2 I 4x2 Hi-Rider 4x4
Front axle
Bearing type Taper roller bearing
Rear axle
Support type Semi-floating
Casing Banjo type
Length (mm {in}) 739 {29.1}
Diameter (mm {in}) 35.0 {1.4}
Rear differential
Reduction gear Hypoid gear
Differential gear Straight bevel gear
Ring gear size (Inches) 8.0 8.9
Final gear ratio 3.909 3.416 I 3.727
Grade API service GL-5
Differential Viscosity SAE 90
Type
oil Capacity 1.40
{1.48, 1.23}
2.45
{2.32, 2.04}
I 2.35 {2.22, 1.96}
. (L {US qt, Imp qt})
Front differential
Reduction gear - Hypoid gear
Differential gear - Straight bevel gear
Ring gear size (Inches) - 8.00
Final gear ratio - 3.727
Grade - API service GL-5
Above -18°C {O OF}:
SAE90
Differential Viscosity -
Type Below -18°C {O OF}:
oil SAE80
Capacity -
1.9 {1.8, 1.6}
(L {US qt, Imp qt}) -
Front drive shaft
Wheel side - Bell joint
Joint type
Differential side - Double offset joint
Shaft diameter (mm {in}) - 30.0 {1.18}
Front propeller shaft
L1 - 45.3 {1.78}
Length (front) (mm {in}) L2 - 552.1 {21.74}
L3 - 45.3 {1.78}
Outer diameter
(mm {in}) D - 63.5 {2.50}
(front)
Rear propeller shaft
L1 159 {6.26} 163.4 {6.433} 41.1 {1.62}
Length (rear) (mm {in}) L2 666.1 {26.22} 670.6 {26.40} 443.6 {17.46}
L3 956.1 {37.64} 909.8 {35.82} I 890.3 {35.05} 896.3 {35.29}
Outer diameter
(mm {in}) D 63.5 {2.50}
(rear)
Joint type Cross-shaped joint
03-00-2
OUTLINE
Item Specification
Engine WL-3 WL-C WE-C
Vehicle type 4x2 4x2 4x2 Hi-Rider 4x4
R15M-D D D
ef-----:---==1~--+-=:=--±-1 ~t
i!E3»F---------:---£---------f11-
S15MX-D 4x4 FRONT D
tr=~----~---~-
S15M-D 4x2 (HI-RIDER) REAR D
r:,-[f=-~--~---+~
03-00-3
OUTLINE
Item Specification
Engine WL-3 WL-C I WE-C
,f
I
.'
Vehicle type 4x2 4x2 4x2 Hi-Rider 4x4 I.

."
Transfer
Mercon® MUlti-
Type - purpose AFT XT-2-
QDX
Transfer oil
Oil capacity
(L {US qt,
(approx.
Imp qt})
- 1.85 {1.95, 1.63}
quantity)
03-00-4
OUTLINE
DRIVELINEIAXLE SPECIFICATIONS [RANGER (5R55S)]
id030000100211
Item Specification
Engine WL-C WE-C
Transmission type 5R55S
Vehicle type 4x2 4x2 Hi-Rider 4x4
Front axle
Rear axle
Support type Semi-floating
Casing Banjo type
Length (mm {in}) 739 {29.1}
Diameter (mm {in}) 35.0 {1.4}
Rear differential
Reduction gear Hypoid gear
Differential gear Straight bevel gear
Ring gear size (Inches) 8.9
Final gear ratio 3.416 3.727
Grade API service GL-5
Viscosity SAE90
Differential
Type Capacity
oil.
(approx. quantity) 2.45 {2.32, 2.04} 2.35 {2.22, 1.96}
(L {US qt, Imp qt})
Front differential
Reduction gear - Hypoid gear
Differential gear - Straight bevel gear
Ring gear size (Inches) - 8.00
Final gear ratio - 3.727
Grade - API service GL-5
Above -18°C {O OF}:
SAE90
Viscosity - Below -18°C {O OF}:
Differential
Type SAE80
oil
Capacity
(approx. quantity) - 1.9 {1.8, 1.6}
(L {US qt, Imp qt})
Front drive shaft
Wheel side - Bell joint
Joint type
Differential side - Double offset joint
Shaft diameter (mm {in}) - 30.0 {1.18}
Front propeller shaft
L1 - 13.2 {0.52}
Length (front)
,
(mm {in}) L2 - 588.4 {23.17}
L3 - 34.3 {1.35}
Outer diameter
(front)
(mm {in}) D - 26.5 {1.04}

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

D D
L1 L2 L3
5R55S 4x4 FRONT
L1
~
IlliJfJl----
1
--l-I_--"-'I~ L2 L3
5R55S 4x4 REAR
D
( .
L3
Transfer case
High 1.000
Gear ratio t - : - = - - - - - - - - - - - + - - - - - - - - - - - - - - - - - - + - - - - - = - - : - : - : : - - - - - - J
Low 2.480
Type Mercon® V
Transfer Oil capacity
(L {US qt,
case oil (approx. 1.2 {1.3, 1.1}
Imp qt})
quantity)
I.· ...;
03-00-4b
ON-BOARD DIAGNOSTIC
03-02 ON-BOARD DIAGNOSTIC

ON-BOARD DIAGNOSTIC OUTLINE
[REMOTE FREEWHEEL (RFW)] ..... 03-02-1
./
ON-BOARD DIAGNOSTIC OUTLINE [REMOTE FREEWHEEL (RFW)]

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

DTC stored in
DTC Malfunction location
memory
P1812 RFW Lock solenoid valve circuit failure X
P1813 RFW Lock solenoid valve open circuit X
P1814 RFW Lock solenoid valve circuit/short to battery X
P1815 RFW Lock solenoid valve circuit/short to ground X
P1878 RFW Free solenoid valve circuit failure X
P1879 RFW Free solenoid valve open circuit X
P1880 RFW Free solenoid valve circuit/short to battery X
P1885 RFW Free solenoid valve circuit/short to ground X
Simulation Item Table (Related to the RFW)

Item Output part Operation Test condition
4WDMODE_L 4x4 indicator light Off/On
HUBLOCK RFW lock solenoid valve Off/On
Engine switch at ON
HUBLOCK_L RFW free solenoid valve Off/On
NTFLAMP RFW indicator light Off/On
03-02-1
ON-BOARD DIAGNOSTIC

ON-BOARD DIAGNOSTIC OUTLINE
[4x4 control module] .............. 03-02-1 ,I.
\- .
'
ON-BOARD DIAGNOSTIC OUTLINE [4x4 control module]

id0302a11 001 00
Special Features
• When a 4x4 control system malfunction is detected, the 4x4 indicator light and 4L indicator light are flashed to
notify the occurrence of the malfunction.
Memory Function
• The memory function records signal systems which have been determined to be abnormal by the malfunction
detection function, and the recorded malfunction information is not cleared even when the engine switch is
turned off (LOCK position) or the malfunction is repaired.
• Refer to the Workshop Manual for the DTC clearing procedure.
Malfunction Indication Function

• The malfunction indication function flashes the 4x4 indicator light and 4L indicator light as a DTC based on the
signal determined to be a malfunction by the malfunction detection function.
DTCTable
DTC stored in
DTC No. Malfunction location
memory
4x4 control module malfunction x
2 Motor component (shift motor) malfunction x
3 Clutch coil malfunction x
4 Speed sensor malfunction x
5 Solenoid valve malfunction . x
6 4x4 switch malfunction x
7 Motor component (position sensor) malfunction x
'-.~
03-02-2
FRONT AXLE
03-11 FRONT AXLE

FRONT AXLE OUTLINE ............. 03-11-1 FRONT AXLE
CROSS-SECTIONAL VIEW .......... 03-11-1
FRONT AXLE OUTLINE

dcf0311 04000101
• Taper roller bearings, which have a large load capacity, are used as wheel bearings, thus preload adjustment
is necessary.
FRONT AXLE CROSS-SECTIONAL VIEW

dcf0311 04000102
4x2 Hi-Rider 4x4
ABS
WHEEL-SPEED
SENSOR
TAPER
ROLLER TAPER TAPER
BEARING ROLLER ROLLER
(SEPARATE- BEARING BEARING
TYPE) (UNIT-TYPE) (UNIT-TYPE)
DCF311ZTB001
03-11-1
REAR AXLE
03-12 REAR AXLE

REAR AXLE OUTLINE . ............. 03-12-1 REAR AXLE
CROSS-SECTIONAL ViEW .......... 03-12-1
REAR AXLE OUTLINE

dcf03120500Ot01
• Taper roller bearings are used as wheel bearings.

• Bearing end play in the axial direction is adjusted using shims between the rear wheel hub and the axle casing.
REAR AXLE CROSS-SECTIONAL VIEW

dcf03120500Ot02
WITHOUTABS WITHABS
ABS
WHEEL-SPEED
SENSOR
AXLE CASING
DBG312ZTB001
03-12-1
DRIVE SHAFT
03-13 DRIVE SHAFT

FRONT DRIVE SHAFT OUTLINE ...... 03-13-1 FRONT DRIVE SHAFT
FRONT DRIVE SHAFT OUTLINE

dcf03132550Ot01
• The bell joint has been adopted on the wheel side and the double offset joint has been adopted on the
differential side to reduce noise and vibration.
FRONT DRIVE SHAFT CROSS-SECTIONAL VIEW

dcf03132550Ot02
WHEEL SIDE DIFFERENTIAL SIDE

BELL JOINT DOUBLE OFFSET JOINT
RIGHT SIDE
WHEEL SIDE DIFFERENTIAL SIDE

BELL JOINT DOUBLE OFFSET JOINT
LEFT SIDE
DBG313ZTB001
03-13-1
~ .
( .
DIFFERENTIAL
03-14 DIFFERENTIAL
REAR DIFFERENTIAL OUTLINE ...... 03-14-1 REAR DIFFERENTIAL
REAR DIFFERENTIAL OUTLINE

dcf031427100to1
• There are two types of differentials available, standard differential and limited slip differential (LSD).
• The purpose of the LSD is to provide driving force to both tires by preventing either tire from slipping.
• With a standard differential, if a tire starts spinning due to poor traction such as mud or snow, the driving force
is exerted on that tire by the action of the differential. With the LSD, the differential action is automatically
limited and driving force is exerted on both tires.
REAR DIFFERENTIAL CROSS-SECTIONAL VIEW

dcf031427100l02
STANDARD DIFFERENTIAL LSD
WITH REAR ASS
ASS SENSOR ROTOR
DCF314ZTB001
03-14-1
TRANSFER [5R55S]
03-16 TRANSFER [SRSSS]

TRANSFER CASE SPEED SENSOR
OUTLINE [5R55S] .. ............... 03-16-1 CONSTRUCTION [5R55S] . ......... . 03-16-9
TRANSFER CASE MOTOR POSITION
STRUCTURAL VIEW [5R55S] ....... 03-16-1 DETECTION SWITCH
TRANSFER CASE FUNCTION [5R55S] ................ 03-16-9
POWER FLOW [5R55S] ............ 03-16-4 MOTOR POSITION
TRANSFER CASE DETECTION SWITCH
ELECTRONIC CONTROL SYSTEM CONSTRUCTION/OPERATION
OUTLINE [5R55S] .. ............... 03-16-8 [5R55S] . ........................ . 03-16-10
TRANSFER CASE MOTOR CONSTRUCTION [5R55S] ..... 03-16-10
SYSTEM WIRING DIAGRAM CLUTCH COIL
[5R55S] ......................... 03-16-8 CONSTRUCTION [5R55S] . ......... . 03-16-11
TRANSFER CASE OUTLINE [5R55S]

id0316c1137500
• A chain-type transfer drive has been adopted for 4x4 driving to improve noise suppression. In addition, the
drive sprocket, which drives the chain, rotates only during 4x4 driving to improve noise suppression during 4x2
driving .
• Shifting between 4x2 HIGH, 4x4 HIGH, and 4x4 LOW is performed by the motor for improved operability.
TRANSFER CASE STRUCTURAL VIEW [5R55S]
TRANSFER CASE
arnffn00000404
03-16-1
'w
Exploded vie
18
3
4
I r'C~enter transfer case
Dowel pin
Bearing
Snap ring
6
7
8 Dowel pin
.
Front transfer cas=e =-___=_
Center transfer case c_omponent
-'---_
5 Oil seal 9 Snap ring

Front transfer ~co§mp~o~nen~t_ __
ca~
03-16-2
TRANSFER [SRSSS]
11 Clip 49 Drive sprocket

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

• During 4x2 driving, drive force from the transmission is transmitted from the input shaft to the output shaft
through the reduction hub, and the drive force from the output shaft is transmitted to the rear differential
Shifting between 4x2 and 4x4 is performed using the lockup component operation. During 4x2 driving, drive
force is not transmitted to the chain because the lockup component does not contact the clutch housing,
therefore, the drive force is not transmitted to the front differential.
REAR DIFFERENTIAL ~ ~ TRANSMISSION

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

SIDE ~ ~SIDE
LOCKUP
COMPONENT
CHAIN
LOCKUP SHIFT FORK

COMPONENT
LOCKUP LOCKUP
HUB COLLAR LOCKUP
COLLAR
CLUTCH
\ CLUTCH LOCKUP
LOCKUP CLUTCH
HOUSING COMPONENT HOUSING HOUSING HUB
arnffn00000337
03-16-5
TRANSFER [SRSSS]
Shifting From 4x4 HIGH to 4x2 HIGH
• When the 4x4 switch is switched to the 2H position while in 4x4 HIGH, the motor rotates from the 4H to 2H
position. Due to the motor rotation, the cam rotates via the shift shaft. The lockup shift fork component slides
due to the cam rotation and spring force of the return spring, and separates from the clutch housing. At this
time, the clutch coil is not energized.When the lockup shift fork component separates from the clutch housing,
drive force transmission to the lower output side is interrupted, and drive force is transmitted only to the rear
differential.
REAR DIFFERENTIAL ./L-, ~ TRANSMISSION

SIDE ~ ~SIDE
CHAIN
CLUTCH
HOUSING
LOCKUP
COLLAR
CLUTCH LOCKUP
HOUSING HUB
arnifn00000338
03-16-6
TRANSFER [5R55S]
Shifting From 4x4 HIGH to 4x4 LOW
• When the 4x4 switch is switched to the 4L position while in 4x4 HIGH, the motor rotates from the 4H to 4L
position. Due to the motor rotation, the cam rotates via the shift shaft. When the cam rotates the reduction shift
fork component, which is fitted into the cam groove, slides, and the reduction hub engages with the spline
which is inside the carrier of the planetary gear component. If the drive force is transmitted to the input shaft in
this condition, the output speed is reduced due to the planetary gear operation, and the rotational torque
increases.This drive force is transmitted to the front and rear differentials.
REAR DIFFERENTIAL
SIDE
¢ ~ TRANSMISSION
L-y/ SIDE
INPUT
SHAFT
REDUCTION
SHIFT FORK
COMPONENT
REDUCTION HUB
CAM
arnffn00000339
Shifting From 4x4 LOW to 4x4 HIGH

• When the 4x4 switch is switched to the 4H position while in 4x4 LOW, the motor rotates from the 4L to 4H
position. Due to the motor rotation, the cam rotates via the shift shaft. When the cam rotates the reduction shift .
fork component, which is fitted into the cam groove, slides, and the reduction hub engages with the input shaft
spline. Due to this, the drive force from the input shaft is transmitted to the output shaft without being input to
the planetary gear, and then it is transmitted to the front and rear differential with the output speed and
rotational torque remaining unchanged.
REAR DIFFERENTIAL
SIDE
¢ ~ TRANSMISSION
L-y/ SIDE r------------------,
INPUT
SHAFT
REDUCTION
SHIFT FORK
COMPONENT
REDUCTION HUB
CAM
arnffn00000340
03-16-7
-,
TRANSFER [5R55S]
TRANSFER CASE ELECTRONIC CONTROL SYSTEM OUTLINE [5R55S]
id0316c1137600
• A 4x4 control module has been adopted which operates the motor according to signals from the speed sensor
and motor position detection switch to control shifting between 4x2 HIGH, 4x4 HIGH, and 4x4 LOW.
TRANSFER CASE SYSTEM WIRING DIAGRAM [5R55S]

id0316c1137700
4x4
CONTROL
B+ IG1
MODULE
TRANSFER CASE
CLUTCH COIL
TCM
MOTOR COMPONENT
DLC
DIGITAL TR SENSOR J : i - - - - - {
LOCK SOLENOID
FREE SOLENOID
arnffw00001937
03-16-8
TRANSFER [5R55S]
SPEED SENSOR CONSTRUCTION [5R55S]
id0316c1137000
• The speed sensor detects the output shaft rotation speed, and the signal is input to the 4x4 control module.
• Signals from the speed sensor are used by the 4x4 control module to perform each control.
SPEED SENSOR
SPEED SENSOR OUTPUT SHAFT
MOTOR POSITION DETECTION SWITCH FUNCTION [5R55S]

id0316c1137100
• The motor position detection switch detects the motor position and outputs control signals to the 4x4 control
module.
• The 4x4 control module determines the motor position according to the signals from the motor position
detection switch.
03-16-9
TRANSFER [SRSSS]
MOTOR POSITION DETECTION SWITCH CONSTRUCTION/OPERATION [5R55S]
id0316c1137200
• The motor position detection switch is integrated into the motor, and turns on or off according to the motor
position.
• The motor position detection switch detects the motor position using a combination of four switches.
Motor Position Position 1 Position 2 Position 3 Position 4
2H Off On Off On
4H On On Off Off
4L Off Off On On
2H
4L
IZ]:SWITCHON A: POSITION 4 D: POSITION 1

B: POSITION 3 E: GROUND
D: SWITCH OFF C: POSITION 2
arnffn00000342
MOTOR CONSTRUCTION [5R55S]

id0316c1137300
• The motor switches between 4x2 HIGH, 4x4 HIGH, and 4x4 LOW according to the signals from the 4x4 control
module.
• A switch for motor position detection is integrated in the motor.
MOTOR
arnffn00000343
03-16-10
TRANSFER [5R55S]
CLUTCH COIL CONSTRUCTION [5R55S]

id0316c1137400
• The clutch coil is integrated in the transfer.
• When a 4x4 shift signal is input to the 4x4 control module, electricity flows from the control module to the clutch
coil and magnetic force is generated. Using the magnetic force, the lockup collar is pulled toward the clutch
housing, shifting from 4x2 to 4x4.
CLUTCH COIL
03-16-11
TRANSFER
03-16 TRANSFER
TRANSFER OUTLINE . .............. 03-16-1 TRANSFER
TRANSFER POWER FLOW . ......... . 03-16-2
TRANSFER OUTLINE
dcf031600000t01
• The transfer of S1SMX-D manual transmission is a chain-drive part-time transfer in which the shift activates
mechanically.
• The speed selection is controlled by a single-lever shift mechanism that provides N, 2H, 4H and 4L.
• The purpose of the transfer is for transmission of driving force to either the rear differential only or to the front
and rear differentials simultaneously.
• The transfer employs a chain to transfer the driving force to the front differential.
• The transfer is a non-synchro type transmission.
• The chain is a maintenance-free type, requiring no tension adjustment.
TRANSFER CROSS-SECTIONAL VIEW

dcf031600000t02
INPUT GEAR LOW GEAR DRIVE SPROCKET
OUTPUT SHAFT
FROM
TRANSMISSION
SHIFT PATTERN
FRONT DRIVE
COUNTER GEAR SPROCKET
TO FRONT
PROPELLER
SHAFT
+
CHAIN
DCG316ZTB001
03-16a-1
TRANSFER
TRANSFER POWER FLOW
dcf031600000to3
2H (2-HIGH) N (NEUTRAL)
4H (4-HIGH) 4L (4-LOW)
DCG316ZTB002
03-16a-2
4-WHEEL DRIVE
03-18 4-WHEEL DRIVE

REMOTE FREEWHEEL (RFW) REMOTE FREEWHEEL (RFW)
OUTLINE ••.••.....•............. 03-18-1 SYSTEM DIAGRAM ••..•.....•..... 03-18-3
CONSTRUCTION ....••......•.•.• 03-18-1 SYSTEM WIRING DIAGRAM ......... 03-18-4
COMPONENTS AND FUNCTIONS ...• 03-18-2 OPERATION ............•.•..•..•. 03-18-4
REMOTE FREEWHEEL (RFW) OUTLINE

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

dcf031827300l02
FRONT DIFFERENTIAL
SLEEVE
DRIVE PINION GEAR

RFW ACTUATOR
DBG314ZTB012
03-18-1
4-WHEEL DRIVE
REMOTE FREEWHEEL (RFW) COMPONENTS AND FUNCTIONS
dcf031827300t03
Electrical component
Part name Function
PCM (RFW control) • Sends ON/OFF signals to lock and free solenoids and indicator lights
according to signals from various switches
Transfer neutral switch • Detects transfer select lever N position
Input
4x4 indicator light • Detects transfer select lever 2H position
RFW switch • Detects RFW unit "lock"
RFW main switch • Creates RFW unit "free"
• Switched ON/OFF by electrical signals from PCM
• Regulates RFW unit "lock" or "free"
Solenoid
ILock • Switched ON when "locked"
Output
IFree • Switched ON when "free"
4x4 indicator light • Illuminates when 4H or 4L selected
RFW indicator light • Illuminates when RFW unit locked
Mechanical component
Part name Function
Transfer select lever • Sets transfer case operation mode (2H, 4H, N, or 4L)
RFW unit • Transmits front propeller shaft rotation to front tires
RFW actuator • "Locks" or ''free'' RFW unit
One-way check valve • Prevents leakage of vacuum
Relationship of Component and Function

Part name Input Output
Transfer 4x4 RFW 4x4 RFW
RFW Lock Free
neutral indicator main indicator indicator
switch solenoid solenoid
Function switch switch switch light light
Controll~d by driver x x x
Controlled by RFW unit x
Controlled by PCM x x x x
03-18-2
4-WHEEL DRIVE
REMOTE FREEWHEEL (RFW) SYSTEM DIAGRAM
dcf031827300to4
4x4 RFW
INDICATOR INDICATOR
LIGHT LIGHT
A: TRANSFER NEUTRAL SWITCH [XJ IR.F.W·I

LOCK
B: 4x4 INDICATOR SWITCH

TO BATTERY FRONT
4H N
DIFFERENTIAL
2~",4L
TRANSFER
SELECT RFW
LEVER ACTUATOR
ENGINE
SWITCH
I-.....------.,...---,-J RFW UNIT
RFWSWITCH
ONE-WAY
CHECK VALVE
DBG314ZTB003
03-18-3
4-WHEEL DRIVE
REMOTE FREEWHEEL (RFW) SYSTEM WIRING DIAGRAM
dcf03182730Ot05
MAIN RELAY
ENGINE
SWITCH
RFW FREE
SOLENOID
T
BATTERY
PCM (RFW CONTROL)
DBG318ZTB001
REMOTE FREEWHEEL (RFW) OPERATION

dcf03182730Ot06
2H (free) to 4H Selection
• The remote freewheel (RFW) unit is automatically locked when the select lever is moved from 2H to 4H while
the vehicle is stopped. At this time, the 4x4 indicator light and the RFW indicator light illuminate to inform the
drive that the vehicle is in four-wheel-drive mode and that the RFW unit is locked. .
Caution
• The changeover from 2H (free) to 4H (locked) MUST NOT be made while the vehicle is moving
because it may result in damage to the front differential and RFW components.
If such a shift is made by mistake, a ratching noise may be heard. In this case return the select
lever to 2H and press the RFW main switch.
4H to 2H (free) Selection
• The RFW unit will be automatically freed when the RFW main switch is pressed once after the select lever is
moved (while the vehicle is moving or while the vehicle is stopped) from 4H to 2H. At this time, the 4x4 indicator
light and the RFW indicator light go OFF to inform the driver that the vehicle is in 4x2 mode and that the RFW
unit has been freed.
Note
• The RFW unit will remain locked only if the RFW main switch is pressed while the vehicle is operating in
4H or 4L.
2H (lock) to 4H, or 4H to 2H (lock) Selection

• If the RFW unit is locked, the transfer case can be changed from 2H to 4H or vice versa while the vehicle is
running. At this time, the RFW indicator light remains illuminated to inform the driver that the RFW unit remains
locked.
4H to 4L, or 4L to 4H Selection
• As with a conventional 4x4, the transfer case can be shifted from 4H to 4L or vice versa when depressing the
clutch while the vehicle is stopped and the engine is running. At this time, the RFW unit remains locked, and the
4x4 and RFW indicator lights remain illuminated.
03-18-4
4-WHEEL DRIVE
Transmission Oil Temperature Increase Prevention
• If the vehicle is driven at high speed with the RFW locked, the temperature of the oil for operating the
transmission, transfer, and front differential increases, resulting in internal part damage. Due to this, the RFW
indicator light flashes (0.3 s intervals) to alert the driver when the following condition is met:
Vehicle is driven at 100 km/h {62 MPH} or more with the RFW locked.
- When the vehicle speed decreases to less than 95 km/h {59 MPH} from the above condition, the RFW
..
indicator light illuminates again. (Normal indication)
Remote Freewheel Unit: FREE
FRONT DIFFERENTIAL
SLEEVE
JOINT SHAFT
RING GEAR
DRIVE PINION GEAR

RFW ACTUATOR
FRONT PROPELLER SHAFT
DBG314ZTB005
• The RFW actuator pulls the sleeve away from the front differential output shaft, allowing the front differential to
rotate freely.
The rotation of the right front tire is absorbed by the front differential, with the result that the ring gear, drive
pinion gear, and front propeller shaft do not turn.
03-18-5
4-WHEEL DRIVE
Remote Freewheel Unit: LOCK
FRONT DIFFERENTIAL
JOINT
RFWUNIT
RFW ACTUATOR
DBG314ZTB006
• The RFW actuator pushes the sleeve over the output shaft, and the front differential output shaft and joint shaft
are coupled together.
If the sleeve and the output shaft are not aligned when actuated, the RFW actuator applies pressure to the
sleeve unit it can slide into place.
The rotation of the front propeller shaft is then transferred, via the front differential, to the front tires, and four-
wheel-drive operation is possible.
03-18-6
4-WHEEL DRIVE
2H (free) to 4H Selection
4x4 RFW
INDICATOR INDICATOR
LIGHT LIGHT
,\\1/, ,\111,-
A: TRANSFER NEUTRAL SWITCH: OFF
B: 4x4 INDICATOR SWITCH: OFF
:00
// ,\
JR.F.w·1
/
LOCK
\
-:....
--...
'.
TO BATTERY FRONT
~
4H
2H DIFFERENTIAL
...., ,
, I \
\
ENGINE TRANSFER ",;\

SWITCH SELECT RFW
LEVER ACTUATOR
ON
RFWSWITCH
Lo---
RF~
MAI~ ~
SWITCH
---.- TO VACUUM PUMP

ONE-WAY
CHECK VALVE
DBG314ZTB007

RFW
Transfer 4x4 RFW 4x4 RFW actuator
RFW Lock Free
neutral indicator main indicator indicator Position
Condition switch switch switch light light
2H-F OFF ON OFF - OFF ON OFF OFF Free
4H-L1 OFF OFF OFF - ON OFF ON OFF Lock
4H-L OFF OFF ON - ON OFF ON ON Lock
• When the select lever is moved from 2H (2H-F in peM) to 4H, the 4x4 indicator switch (in the transfer case
switch) changes from ON to OFF. As a result, the peM establishes a condition known as 4H-L1' and the lock
solenoid is switched ON, causing the actuator to move toward the lock side. At the same time, the 4x4 indicator
light is illuminated.
When the RFW unit is fully locked, the RFW switch is switched ON, and condition 4H-L is established in the
peM. The RFW indicator light illuminates to notify the driver that the RFW is locked.
03-18-7
4-WHEEL DRIVE
4H to 2H (lock) Selection
4x4 RFW
INDICATOR INDICATOR
LIGHT LIGHT

. .)1///
IR.F.W·I
LOCK
-:....
-.........
B: 4x4 INDICATOR SWITCH: ON
// \ '.
TO BATTERY FRONT
DIFFERENTIAL
ENGINE
SWITCH RFW
ACTUATOR
LOCK
ON
---
RFn
MAIN
SWITCH
----.. TO ~ACUUM PUMP

ONE-WAY
CHECK VALVE
DBG314ZTB008

RFW
RFW Lock Free
4H-F OFF OFF ON - . ON OFF ON ON Lock
2H-L OFF ON ON OFF ON OFF OFF ON Lock
• When the select lever is moved from 4H (4H-L condition) to 2H, the 4x4 indicator switch (in the transfer case
switch) changes from OFF to ON.
If the RFW main switch is in the OFF position, condition 2H-L is established, the lock solenoid remains ON, and
the RFW actuator is held at the lock position. At this time, the 4x4 indicator light is switched OFF.
03-18-8
4-WHEEL DRIVE
2H (lock) to 2H (free) Selection
4x4 RFW
INDICATOR INDICATOR
LIGHT LIGHT
A: TRANSFER NEUTRAL SWITCH: OFF IR.F.W·I

LOCK
B: 4x4 INDICATOR SWITCH: ON
TO BATTERY FRONT
DIFFERENTIAL
~-,
ENGINE TRANSFER
SWITCH SELECT RFW
LEVER ACTUATOR ,, ,
,,
,,
,
ON
RFWUNIT
RFWSWITCH
1(Zz:2'ZZZ~~ ---.- TO VACUUM PUMP

ONE-WAY
CHECK VALVE
DBG314ZTB009

RFW
RFW Lock Free
2H-L OFF ON ON OFF ON OFF OFF ON Lock
2H-F1 OFF ON OFF ON OFF ON OFF OFF Free
2H-F OFF ON OFF - OFF ON OFF OFF Free
• When the above condition (2H-L) the RFW main switch is pressed once (ON), condition 2H-F1 is established,
the RFW indicator light is switched OFF, and, same time, the free solenoid is switched ON, and the actuator is
pulled to the free side. When the RFW unit becomes fully free, the RFW switch is turned OFF, and 2H-F
condition is established.
03-18-9
4-WHEEL DRIVE
4H to 4L or 4L to 4H Selection
4x4 RFW
INDICATOR, INDICATOR
LIGHT LIGHT
A: TRANSFER NEUTRAL SWITCH: OFF-ON

,\\1/,
-"";_T
/~\
I,\\11,...
R,F,w.1 -:....
LOCK ___
B: 4x4 INDICATOR SWITCH: ON / \ '.
4H TO BATTERY FRONT
DIFFERENTIAL
ENGINE
SWITCH
ON
RFWSWITCH
---
RF~
MAI~ ,J,..
SWITCH
--.. TO VACUUM PUMP

ONE-WAY
CHECK VALVE
DBG314ZTB010

RFW
RFW Lock Free
N ON OFF ON - ON OFF OFF ON Lock
• When the select lever is moved from 4H to 4L (both 4H-L in the peM) or vice versa, there is a change to the
neutral condition midway through the changeover thereby momentarily switching ON the transfer neutral switch
(in the transfer case switch), and switching OFF the 4x4 indicator light.
During 4H or 4L operation, the lock solenoid is ON (as a result of 4H-L condition), and the RFW actuator is held
in the lock position. If the RFW main switch is pressed at this time, there is no effect upon the RFW actuator.
03-18-10
4-WHEEL DRIVE
Engine Switch Turned from OFF to ON
4x4 RFW
INDICATOR INDICATOR
LIGHT LIGHT
B: 4x4 INDICATOR SWITCH: ON 00 IR.F.W·I
LOCK
TO BATTERY FRONT
DIFFERENTIAL
ENGINE TRANSFER
SWITCH SELECT
RFW
LEVER
ACTUATOR
PCM
(RFW
CONTROL)' RFWSWITCH
ONE-WAY
CHECK VALVE
DBG314ZTB011

RFW
RFW Lock Free
2H-L OFF ON OFF - OFF ON OFF OFF Free
2H-L OFF ON OFF OFF OFF ON OFF OFF Free
• When the ignition switch is turned from OFF to ON, the switches and solenoid are activated to provide the
same RFW condition as when it was turned off.
03-18-11
4-WHEEL DRIVE [AT (SRSSS)]
03-18 4-WHEEL DRIVE [AT (SRSSS)]

4x4 CONTROL SYSTEM 4x4 CONTROL SYSTEM
OUTLINE [AT (SRSSS)] . ............ 03-18-1 SYSTEM DIAGRAM [AT (SRSSS)] ..... 03-18-3
4x4 CONTROL SYSTEM 4x4 CONTROL SYSTEM
CONSTRUCTION [AT (SRSSS)] ...... 03-18-1 SYSTEM WIRING DIAGRAM
4x4 CONTROL SYSTEM [AT (SRSSS)] ..................... . 03-18-4
COMPONENTS AND FUNCTIONS 4x4 CONTROL SYSTEM
[AT (SRSSS)] ..................... 03-18-2 OPERATION [AT (SRSSS)] . ......... . 03-18-4
4x4 CONTROL SYSTEM OUTLINE [AT (SRSSS)]

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

RFW ACTUATOR
arnffn00000273
03-18-1
4x4 CONTROL SYSTEM COMPONENTS AND FUNCTIONS [AT (5R55S)]
id0318d2164000
Electrical component
Part name Function
4x4CM • Sends ON/OFF signals to lock and free solenoids and indicator lights
according to signals from various switches
Digital TR sensor • Detects selector lever N position
Input 4x4 switch • Detects 4x4 switch 2H, 4H or 4L position
Speed sensor • Detects output shaft speed
• Switched ON/OFF by electrical signals from 4x4 CM
Solenoid
• Regulates RFW unit "lock" or "free"
Lock • Switched ON when "locked"
Output
Free • Switched ON when "free"
Motor component (transfer case) • Sets transfer case operation mode (2H, 4H or 4L)
Clutch coil (transfer case) • Operates when 4H or 4L selected
4x4 indicator light • Illuminates when 4H or 4L selected
4L indicator light • Illuminates when 4L selected
Mechanical component
Part name Function
RFW unit • Transmits front propeller shaft rotation to front tires
RFW actuator • "Locks" or ''free'' RFW unit
One-way check valve • Prevents leakage of vacuum
Motor component (transfer
case) • Motor operates to slide each shift fork
Clutch coil (transfer case) • Magnetic force occur in clutch coil during operation to pull the lockup component
Relationship of Component and Function

Digital Motor 4x4 4L
4x4 Speed Lock Free Clutch
TR compon indicator indicator
switch sensor solenoid solenoid coil
Function sensor ent light light
Controlled by driver x x
Controlled by 4x4 CM x x x x x x x
03-18-2
4x4 CONTROL SYSTEM SYSTEM DIAGRAM [AT (5R55S)]
id0318d2163800
FRONT
DIFFERENTIAL
4x4 4L
INDICATOR INDICATOR RFW
LIGHT LIGHT ACTUATOR
TO BATTERY
[XJ ~
DIGITAL TR SENSOR
EXCEPT
N POSITION
TO BATTERY TRANSMISSION
4x4SWITCH
N POSITION
/4H~
2H 0 4L
ENGINE
SWITCH
4x4CM
arnffn00000399
03-18-3
4x4 CONTROL SYSTEM SYSTEM WIRING DIAGRAM [AT (5R55S)]
id0318d2163900 .
4x4
CONTROL
B+ IG1
MODULE
TRANSFER CASE
~--~C~--------~
CLUTCH COIL
TCM
MOTOR COMPONENT
DLC
4x4 SWITCH
DIGITAL TR SENSOR J 1 - - - - - (
FREE SOLENOID
arnffw00001937
4x4 CONTROL SYSTEM OPERATION [AT (5R55S)]

id0318d2165000
Note
• Shifting from 2H to 4H or 4H to 2H can be performed whether the vehicle is stopped or driving.
2H to 4H Selection
• When the 4x4 switch is switched from 2H to 4H, the clutch coil and motor in the transfer operate, the lockup
shift fork slides to establish the 4H condition and the RFW unit locks automatically. At this time, the 4x4
indicator light illuminates to inform the driver that the vehicle is in four-wheel-drive mode.
4H to 2H Selection
• When the 4x4 switch is switched from 4H to 2H, the clutch coil in the transfer stops operation but the motor
operates to slide the lockup shift fork and establish the 2H condition. Also, the RFW unit unlocks automatically.
At this time, the 4x4 indicator light turns off to inform the driver that the vehicle is in 4x2 mode.
4H to 4L Selection
• Shifting from 4H to 4L can be performed only when the vehicle is stopped with the selector lever in the N
position. When the 4x4 switch is switched from 4H to 4L, the motor in the transfer operates and the reduction
shift fork slides to establish the 4L condition. At this time, the RFW unit remains locked and the 4x4 indicator
light remains illuminated and, in addition, the 4L indicator light illuminates.
03-18-4
4L to 4H Selection
• Shifting from 4L to 4H can be performed only when the vehicle is stopped with the selector lever in the N
position. When the 4x4 switch is switched from 4L to 4H, the motor in the transfer operates and the reduction
shift fork slides to establish the 4H condition. At this time, the RFW unit remains locked and the 4x4 indicator
light remains illuminated, but the 4L indicator light turns off.
Remote Freewheel Unit: FREE
FRONT DIFFERENTIAL
SLEEVE
JOINT SHAFT
RING GEAR
RFW ACTUATOR
arnffn00000029
• The RFW actuator pulls the sleeve away from the front differential output shaft, allowing the front differential to
rotate freely.
The rotation of the right front tire is absorbed by the front differential, with the result that the ring gear, drive
pinion gear, and front propeller shaft do not turn.
03-18-5
Remote Freewheel Unit: LOCK
FRONT DIFFERENTIAL
JOINT SHAFT
RFW ACTUATOR
arnffn00000030
• The RFW actuator pushes the sleeve over the output shaft, and the front differential output shaft and joint shaft
are coupled together.
If the sleeve and the output shaft are not aligned when actuated, the RFW actuator applies pressure to the
sleeve unit it can slide into place.
The rotation of the front propeller shaft is then transferred, via the front differential, to the front tires, and four-
wheel-drive operation is possible.
03-18-6
2H to 4H Selection
FRONT
4x4 4L DIFFERENTIAL
INDICATOR INDICATOR
LIGHT LIGHT
RFW
,\\11, ACTUATOR
TO BATTERY
:00"
//
DIGITAL TR SENSOR
EXCEPT
N POSITION TRANSFER
POWER FLOW
TO BATTERY
4x4 SWITCH
2H r
/4H~
4L
4x4CM
arnffn00000400

RFW
Digital Motor 4x4 4L actuator
TR compon indicato indicato Position
Condition sensor ent r light r light
2H - 2H - OFF ON 2H OFF OFF OFF Free
4H - 4H - ON OFF 4H ON ON. OFF Lock
• When the 4x4 switch is switched from 2H to 4H, the clutch coil and motor in the transfer operate, the lockup
shift fork slides to establish the 4H condition and the RFW unit locks automatically. At this time, the 4x4
indicator light illuminates to inform the driver that the vehicle is in four-wheel-drive mode.
03-18-7
4H to 2H Selection
FRONT
4x4 4L DIFFERENTIAL
INDICATOR INDICATOR
LIGHT LIGHT
, RFW
ACTUATOR
TO BATTERY
DIGITAL TR SENSOR
EXCEPT
N POSITION TRANSFER
POWER FLOW
TO BATTERY @.~0t
TRANSMISSION
4x4 SWITCH
N POSITION r'--II--'-----I~/ TRANSFER
/4H~ SPEED SENSOR
2H 0 4L
ENGINE
SWITCH
4x4CM
arnffn0000040 1

RFW
4H - 4H - ON OFF 4H ON ON OFF Lock
2H - 2H - OFF ON 2H OFF OFF OFF Free
• When the 4x4 switch is switched from 4H to 2H, the clutch coil in the transfer stops operation but the motor
operates to slide the lockup shift fork and establish the 2H condition. Also, the RFW unit unlocks automatically.
At this time, the 4x4 indicator light turns off to inform the driver that the vehicle is in 4x2 mode.
I: ..
03-18-8
4H to 4L Selection
FRONT
4x4 4L DIFFERENTIAL
INDICATOR INDICATOR
LIGHT LIGHT
RFW
,\\11, ,\11// ACTUATOR
TO BATTERY
:00"//
~:
I, ,-....
LOCK
DIGITAL TR SENSOR
EXCEPT
N POSITION
o TO BATTERY
4x4SWITCH
N POSITION
/4H~ SPEED SENSOR
2H 0 4L
ENGINE
SWITCH
'<Zz22@jF --.. TO VACUUM

PUMP
4x4CM
arnffn00000402

RFW
vehicle
4H N 4H
stop
ON OFF 4H ON ON OFF Lock
vehicle
4L N 4L
stop
ON OFF 4L ON ON ON Lock
• Shifting from 4H to 4L can be performed only when the vehicle is stopped with the selector lever in the N
position. When the 4x4 switch is switched from 4H to 4L, the motor in the transfer operates and the reduction
shift fork slides to establish the 4L condition. At this time, the RFW unit remains locked and the 4x4 indicator
light remains illuminated and, in addition, the 4L indicator light illuminates.
03-18-9
4-WHEEL DRIVE [AT (5R55S)]
4L to 4H Selection
FRONT
4x4 4L DIFFERENTIAL
INDICATOR INDICATOR
LIGHT LIGHT
RFW
,\\11, ACTUATOR
TO BATTERY
:00\'
//
LOCK
DIGITAL TR SENSOR
EXCEPT
N POSITION TRANSFER
o TO BATTERY
POWER FLOW
4x4SWITCH
/4H~
r 4L
4x4CM
arnffn00000403

RFW
vehicle
4L N 4L stop ON OFF 4L ON ON ON Lock
vehicle
4H N 4H stop ON OFF 4H ON ON OFF Lock
• Shifting from 4L to 4H can be performed only when the vehicle is stopped with the selector lever in the N
position. When the 4x4 switch is switched from 4L to 4H, the motor in the transfer operates and the reduction
shift fork slides to establish the 4H condition. At this time, the RFW unit remains locked and the 4x4 indicator
light remains illuminated, but the 4L indicator light turns off.
03-18-10
BRAKES
oUTLI NE . . . . . . . . . . . . . . . . .
04-00 CONVENTIONAL
ON-BOARD DIAGNOSTIC BRAKE SYSTEM .......... 04-11
[REAR ANTI LOCK BRAKE PARKING BRAKE SYSTEM ... 04-12
SYSTEM (ABS)] .. . . . . . . .. 04-02A ANTI LOCK BRAKE SYSTEM
ON-BOARD DIAGNOSTIC [REAR ANTI LOCK BRAKE
[4-WHEEL ANTILOCK BRAKE SYSTEM (ABS)] ........... 04-13A
SYSTEM (4W-ABS)] ....... 04-02B ANTI LOCK BRAKE SYSTEM
[4-WHEEL ANTILOCK BRAKE
SYSTEM (4W-ABS)] ........ 04-13B
04-00 OUTLINE
BRAKE ABBREVIATIONS . .......... 04-00-1 BRAKE SPECIFICATIONS . .......... . 04-00-2
BRAKE FEATURES ................ 04-00-1
BRAKE ABBREVIATIONS
dcf04000000Ot01

CM Control Module
HU Hydraulic Unit
IDS Integrated Diagnostic Software
LF Left Front
LR Left Rear
LSPV Load Sensing Proportioning Valve
PDS Portable Diagnostic Software
RF Right Front
RR Right Rear
SW Switch
4W-ABS 4-Wheel Antilock Brake System
4x2 4-wheel 2-d rive
4x4 4-wheel 4-drive
BRAKE FEATURES
dcf04000000Ot02
Improved safety • 4-wheel antilock brake system (4W-ABS) adopted

• Rear antilock brake system (ABS) adopted
Improved braking force • Tandem diaphragm power brake unit adopted
• Load sensing proportioning valve (LSPV) has been adopted
• Large diameter front disc brakes adopted
• Two-piston type front disc brake caliper adopted (Hi-Rider, 4x4)
• Wide width lining for the rear brake drum adopted
• Vacuum pump adopted
Improved serviceability • Automatic adjustment mechanism rear brake (drum) has been adopted
Size and weight reduction • Integrated construction of the hydraulic unit (HU) and control module (CM) adopted for the ABS
HU/CM (4W-ABS)
04-00-1
OUTLINE
BRAKE SPECIFICATIONS
dcf04000000Ot03
Item Specification
4x2 (except Hi-Rider) Hi-Rider, 4x4
Type Suspended design
Brake pedal Pedal lever ratio 3.68
Max. stroke (mm {in}) 129 {5.08}
Master Type Tandem (with level sensor)
cylinder Cylinder bore (mm {in}) 25.4 {1.00}
Type Ventilated disc
Cylinder bore (mm {in}) 60.5 {2.38} 42.86 {1.687} x 2
Pad dimensions (area x thickness)
Front brake 4,950 {7.673} x 10 {0.39} 5,500 {8.525} x 9 {0.35}
(disc) (mm 2 x mm {in 2 x in})
Disc plate dimensions
(outer diameter x thickness) 256 {10.1} x 24 {0.94} 289 {11.4} x 28 {1.1}
(mm {in})
Type Leading-trailing
Wheel cylinder bore (mm {in}) 23.81 {0.9374}
Lining dimensions
Rear brake (width x length x thickness) 55 {2.2} x 271 {1 O. 7} x 5.5 {0.22} 55 {2.2} x 296 {11.7} x 5.5 {0.22}
(drum)
(mm {in})
Drum inner diameter (mm {in}) 270 {10.6} 295 {11.6}
Shoe clearance adjustment Automatic adjuster
Vacuum multiplier
Power brake Type
Tandem diaphragm
unit
Outer diameter (mm {in}) 188.4 {7.417} + 215.2 {8.472}
Rear wheel
braking force Type Load sensing proportioning valve
control device
Type Mechanical two-rear-wheel control
Parking brake
Operation system Stick lever type
Brake fluid Type SAE J 1703, FMVSS 116 DOT-3
04-00-2
ON-BOARD DIAGNOSTIC [4-WHEEL ANTILOCK BRAKE SYSTEM (4W-ABS)]
04-02B ON-BOARD DIAGNOSTIC [4-WHEEL ANTILOCK

BRAKE SYSTEM (4W-ABS)]
ON-BOARD DIAGNOSTIC SYSTEM ON-BOARD DIAGNOSTIC SYSTEM
OUTLINE [4W-ABS] ............... 04-02B-1 ACTIVE COMMAND MODES
ON-BOARD DIAGNOSTIC SYSTEM FUNCTION [4W-ABS] .............. 04-02B-3
FUNCTION [4W-ABS] . ............. 04-02B-2 ON-BOARD DIAGNOSTIC SYSTEM
ON-BOARD DIAGNOSTIC SYSTEM EXTERNAL TESTER COMMUNICATION
PID/DATA MONITOR FUNCTION FUNCTION [4W-ABS] ............. . 04-02B-4
[4W-ABS] . ....................... 04-02B-3 DLC-2 CONSTRUCTION [4W-ABS] .... 04-02B-5
ON-BOARD DIAGNOSTIC SYSTEM OUTLINE [4W-ABS]

dcf04024375Ot04
• The on-board diagnostic system consists of a malfunction detection system that detects abnormalities in inpuV
output signals when the ignition switch is at the ON position, a data monitor function that reads out specified
inpuVoutput signals and a simulation function that allows for override operation of output parts (such as
solenoid valves).
• The data link connector 2 (DLC-2), which groups together all the connectors used for malfunction diagnosis
and detecting/repair into a single location, has been adopted, thereby improving serviceability. Diagnosis is
performed by connecting the current diagnostic tool to the DLC-2.
• In addition to DTC read-out, the current diagnostic tool is used to clear DTCs using the display screen of the
diagnostic tester, and to access the PID/data monitor and simulation functions, providing enhanced
malfunction diagnosis and improved serviceability.
Block Diagram
ABS
WARNING
LIGHT
ON-BOARD DIAGNOSTIC FUNCTION

,---------------- --------------
I
I
I
MALFUNCTION DISPLAY
I I----~ FUNCTION ~
I
I I
I MEMORY - __I
I FUNCTION - --I
I
I I SERIAL
I
1__ - _~
COMMUNICATION ~ DLC-2
I /
I
I
I
I I
I I
I I
I I
I MALFUNCTION PID/DATA I
I ACTIVE COMMAND I CURRENT
DETECTION MONITOR
I MODES FUNCTION I DIAGNOSTIC
FUNCTION FUNCTION I
I TOOL
A A
I
~
I
I I
I HU I
INSPECTION I
I IFAIL-SAFE I
FUNCTION
~FUNcr_ I
----\7----\7--tt---"
INPUT ~ NORMAL CONTROL AREA
~ OUTPUT
DEVICE DEVICE
vi -V
DCF402BTBOOl
04-028-1
ON-BOARD DIAGNOSTIC [4-WHEEL ANTI LOCK BRAKE SYSTEM (4W-ABS)]
ON-BOARD DIAGNOSTIC SYSTEM FUNCTION [4W-ABS]
dcf04024375ot05
Malfunction Detection Function

• The malfunction detection function detects malfunctions in the input/output signal system of the ASS HU/CM
when the engine switch is at the ON position. [.. '
• When the ASS HU/CM are started up, Jhe following malfunction detections are performed.
The ASS warning light illuminate for approx. 3 s when the engine switch is turned to the ON position. At
the same time, the fail-safe relay is operated, and the input/output signals of each part is monitored for
malfunction diagnosis. After starting to drive, the first time the vehicle speed is approx. 12 km/h {7.5 mph}
or more the pump motor is operated and malfunction diagnosis is performed again.
• When malfunctions are detected, the corresponding lights are illuminated to alert the driver. Using the external
tester communication function, DTCs can be output through the KLN of the OLC-2. At the same time,
malfunction detection results are sent to the memory and fail-safe functions.
Memory Function
• The memory function stores OTCs of malfunctions in input/output signal systems. With this function, once a
OIC is stored it is not cleared after the engine switch has been turned off (LOCK position), even if the
malfunctioning signal system has returned to normal.
• Since the ASS HU/CM has a built-in non-volatile memory, OTCs are not cleared even if the battery is removed.
Therefore, it is necessary to clear the memory after performing repairs. Refer to the Workshop Manual for the
OTC clearing procedure.
Fail-safe Function
• When the malfunction detection function determines a malfunction, each light illuminates to advise the driver.
At this time, the fail-safe function controls the ASS as shown in the fail-safe function table.
Fail-safe Function Malfunction Contents
Fail-safe function
Malfunction location DTC number Warning light illumination status Control status
ABS warning light ABS control
B1317
Power supply system IIluminated*1 Control disabled*2
B1318
ABS HUlCM system B1342 Illuminated Control disabled
Brake switch signal system B1484 Not illuminated Control enabled
C1095
Pump motor, motor relay systems Illuminated Control disabled
C1096
C1145
C1155
ABS wheel-speed sensor system Illuminated Control disabled
C1165
C1175
, Fail-safe relay system C1186 Illuminated Control disabled
C1194
C1198
C1202
Solenoid valve system Illuminated Control disabled
C1206
C1210
C1214
j
ABS wheel-speed sensor (slip
C1222 Illuminated Control disabled
monitor) system
C1233
ABS wheel-speed sensor/ABS C1234
Illuminated Control disabled
sensor rotor systems C1235
C1236
Incorrect ABS HU/CM installed C1414 Illuminated Control disabled
C1730
G sensor system*3 C1949 IlIumhlated Control disabled
C1950 '7
*1 : If the ignition voltage returns to normal, the light goes out.

*2
: If the ignition voltage returns to normal, control is enabled.
*3 : Hi-Rider, 4x4
04-028-2
ON-BOARD DIAGNOSTIC SYSTEM PID/DATA MONITOR FUNCTION [4W-ABS]

dcf040243750106
• The PID/data monitor function is used for optionally selecting input/output signal monitor items preset in the
ASS HU/CM and reading them out in real-time.
UniUCondition
PID/data monitor item InpuUoutput part
(Tester display)
ABS_LAMP ABS warning light On/Off
ABS_VOLT Battery V
ACCLMTR* G sensor G
BOO_ABS Brake switch On/Off
CCNTABS Number of continuous DTCs -
PMP_MOTOR Pump motor On/Off
RLY_PMP Pump motor relay On/Off
RLY_VLV Solenoid valve relay On/Off
V_LF_INL LF inlet solenoid valve On/Off
V_LF_OTL LF outlet solenoid valve On/Off
V_RF_INL RF inlet solenoid valve On/Off
V_RF_OTL RF outlet solenoid valve On/Off
V_ReaUNL Rear inlet solenoid valve On/Off
V_Rear_OTL Rear outlet solenoid valve On/Off
WSPD_LF ABS wheel-speed sensor (LF) KPH,MPH
WSPD_LR ABS wheel-speed sensor (LR) KPH, MPH
WSPD_RF ABS wheel-speed sensor (RF) KPH,MPH
WSPD_RR ABS wheel-speed sensor (RR) KPH, MPH
: Hi-Rider, 4x4
ON-BOARD DIAGNOSTIC SYSTEM ACTIVE COMMAND MODES FUNCTION [4W-ABS]

dcf04024375Ot07
• The active command modes function is used for optionally selecting active command modes items of input/
output parts preset in the ASS HU/CM, and to operate them regardless of CM control.
• To protect the hydraulic unit interior, operate output related parts for only 10 s or less when using the active
command modes function.
Active Command Modes Table

Operation
Command name Output part name Operation
condition
PM P_MOTOR Pump motor
V_LF_INL LF inlet solenoid valve
V_LF_OTL LF outlet solenoid valve
Engine switch at
ON
V_ReacOTL Rear outlet solenoid valve
V_RF_INL RF inlet solenoid valve
V_RF_OTL RF outlet solenoid valve
04-028-3
ON-BOARD DIAGNOSTIC [4-WHEEL ANTI LOCK BRAKE SYSTEM (4W-ABS)] .
ON-BOARD DIAGNOSTIC SYSTEM EXTERNAL TESTER COMMUNICATION FUNCTION [4W-ABS]
dcf04024375ot08
• The external tester communication function enables communication of diagnostic data (OTC read-outs, input!
output signal read-outs, and operation of input/output parts) between the ABS HU/CM and an external tester.
Connections and Communication Contents

External tester
Current diagnostic tool
Connection Communication method
On-board diagnostic
(malfunction detection) Input/output: KLN Serial communication
function
PID/DATA monitor function Input/output: KLN Serial communication
Active command modes
Input/output: KLN Serial communication
function
Serial communication
• Serial communication (two-way communication) allows for multiple data to be sent and received instantly along
the same line.
• By connecting the current diagnostic tool to the OLC-2, diagnostic data can be sent and received between the
current diagnostic tool and the ABS HU/CM using the KLN terminals (within the OLC-2).
• The ABS HU/CM receives the command signals of the malfunction detection function, PID/data monitor
function, and the active command modes function from the current diagnostic tool, and sends OTCs and data
regarding the operating condition and status of each input/output part to the current diagnostic tool.
DBR402ZTB003
Diagnostic function name Signal received Signal sent

Malfunction detection function OTC verification signal OTC
Command signal to read selected Monitored data for requested monitor
PIO/data monitor function
monitor item item
Operation command signal for selected
Active command modes function Input/output part name
active command modes item
04-028-4
DLC-2 CONSTRUCTION [4W-ABS]
dcf04024375Ot09
• A connector (DLC-2) conforming to International Organization for Standardization (ISO) standards has been
added .
• Shape and terminal arrangement as stipulated by the ISO 15031-3 (SAE J1962) international standard has
been adopted for this connector. The connector has a 16-pin construction that includes the KLN, GND1, GND2
and B+ terminals.
DLC-2
DBR402ZTB002
Terminal Function
KLN Serial communication KLN terminal
GND1 Body ground terminal
GND2 Serial communication ground terminal
B+ Battery power supply terminal
04-028-5
CONVENTIONAL BRAKE SYSTEM
04-11 CONVENTIONAL BRAKE SYSTEM
CONVENTIONAL BRAKE LOAD SENSING PROPORTIONING
SYSTEM OUTLINE . ............... 04-11-1 VALVE (LSPV) CONSTRUCTION ..... 04-11-3
CONVENTIONAL BRAKE LOAD SENSING PROPORTIONING
SYSTEM STRUCTURAL ViEW ....... 04-11-1 VALVE (LSPV) OPERATION . ....... . 04-11-4
MASTER CYLINDER FRONT BRAKE (DISC)
CONSTRUCTION . ................ 04-11-2 CONSTRUCTION . ................ . 04-11-6
POWER BRAKE UNIT REAR BRAKE (DRUM)
CONSTRUCTION . ................ 04-11-2 CONSTRUCTION . ................ . 04-11-7
VACUUM PUMP CONSTRUCTION .... 04-11-2 REAR BRAKE (DRUM) OPERATION . . . 04-11-8
CONVENTIONAL BRAKE SYSTEM OUTLINE

dcf041100000t01
• A tandem-type master cylinder has been adopted, improving braking force.

• A large diameter, tandem diaphragm power brake unit has been adopted, improving braking force.
• A large diameter, ventilated disc-type front brake has been adopted, improving braking force.
• A two-piston type front disc brake caliper has been adopted, improving braking force. (Hi-Rider, 4x4)
• A wide width lining for the rear brake drum has been adopted, improving braking force.
• An Automatic adjustment mechanism rear brake (drum) has been adopted, improving serviceability
• A vacuum pump has been adopted, improving braking force.
CONVENTIONAL BRAKE SYSTEM STRUCTURAL VIEW

dcf04110000Qt02
LOAD SENSING
PROPORTIONING VALVE (LSPV)
REAR BRAKE (DRUM)
VACUUM PUMP
DCF411ZTB001
04-11-1
MASTER CYLINDER CONSTRUCTION
dcf04114340Ot01
• A tandem-type master cylinder with a 25.4 mm

{1.00 in} bore has been adopted, improving
braking force.
DBR411 ZTB002
POWER BRAKE UNIT CONSTRUCTION

dcf041143800to1
• A tandem diaphragm type power brake unit has

been adopted for all models, achieving
compatibility between high braking performance
and excellent brake feeling.
DBR411 ZTB003
VACUUM PUMP CONSTRUCTION

dcf041118777to1
• A gear-driven vacuum pump has been adopted,

improving braking force.
DBR411ZTB014
04-11-2
LOAD SENSING PROPORTIONING VALVE (LSPV) CONSTRUCTION
dcf041143903t01
• This valves is to proportion the braking force to the front and rear wheels as ideally as possible for higher safety
at the time of the brakes being applied, it controls the brake fluid pressure to the rear brakes according to the
load on the rear axle so that the rear end of the vehicle may not spin due to locking of the rear wheels in
advance of the fronts.
• This valve also incorporates a bypass passage that prevents pressure reduction so that rear wheels will still
have plenty of braking force to stop the vehicle in the event of a front master cylinder malfunction.
RETAINER
RING VALVE
AXLE CASING
DBR411 ZTBOOB
04-11-3
LOAD SENSING PROPORTIONING VALVE (LSPV) OPERATION
dcf041143903t02
Braking When Vehicle Empty

• The hydraulic pressure generated at the rear section of the master cylinder is applied, via input port 1, to the
hydraulic-pressure control section of the LSPV.
The hydraulic pressure generated at the front section of the master cylinder is applied to the front brakes, and
to the bypass section of the LSPV via input port 2. The rear wheel and front wheel hydraulic pressure are
separated by the X-ring of the plunger. Since port 1 hydraulic pressure is normally equal to port 2 hydraulic
pressure, the plunger is pressed against the cylinder base by L.
When port 1 hydraulic pressure is applied to the plunger, the plunger tries to move to the left. But, because
there is also at the same time force applied in the right direction by the lever link (force L), the plunger is held
against the cylinder base. The result is that the hydraulic pressure at the output side is the same as at the input
side when force L is higher than the input pressure.
PRESSURE IN PRESSURE IN
(REAR) PRESSURE OUT (FRONT)
PORT-1
t ~ PORT-2
w
a:
t
;:)
en
en
w
a:
0... ~~.
I-
;:) , ~~~
0...
I-
-
;:)
0
0 INPUT PRESSURE
RING VALVE
PLUNGER
DBR411ZTB009
• When the input hydraulic pressure increases further and overcomes force L, the plunger is moved slightly
leftward, sealing it against the ring valve. This temporarily separates the input side from the output side. The
output pressure at this time is called the break point. If force L from the lever link changes (i.e. lowering of the
vehicle body), this break point changes accordingly.
PORT-1
PORT-2 ~ w
~t
a:
0...
I-
;:)
0...
I-
-
;:)
o
INPUT PRESSURE
PLUNGER RING VALVE
DBR411 ZTB01 0
04-11-4
• When the input pressure passes the break point, the plunger is moved back against the cylinder base. The
output port is opened, and hydraulic pressure generated at the rear section of the master cylinder is applied to
the rear wheel cylinders.
As the output pressure continues to increase, the plunger is again moved toward the left against the ring valve,
thus separating the input and output side again.
.
This action is repeated to control the output pressure.
~
UJ
~t
a::
0..
I-
::J
0..
I-
::J
o
kP -
INPUT PRESSURE
DBR411ZTB011
Braking When Vehicle Loaded

• The vehicle height (from the ground) decreases when cargo is loaded into the vehicle. This causes the force of
the spring connected to the axle casing to decrease and the force of the spring on the LSPV to increase force
L, increasing the pressure holding the plunger to the right.
II
1:./
The master cylinder hydraulic pressure (input) needed to cause the plunger to move back to the left also
becomes equally higher as a result.
This causes the break point to be increased and extra barking power is provided in accordance with the weight
of cargo loaded.
t ~
I UJ
~t
-------- LOADED
a::
0..
I-
::J
0..
-
I-
::J
o
INPUT PRESSURE
DBR411ZTB012
04-11-5
If Malfunction Of Front Hydraulic System
• If there is a malfunction of the front-brake hydraulic system, the hydraulic pressure from input port 2 becomes
zero. The result is that the input pressure presses the plunger to the right, opening the bypass passage.
The output pressure thus equals the input pressure, and there is so pressure reduction.
PRESSURE IN
PRESSURE IN (FRONT)
(REAR) PRESSURE OUT X
t PORT-2
I
w
~1
a:
0..
I-
:J
0..
I-
-
:J
o
PLUNGER INPUT PRESSURE
DBR411ZTB013
FRONT BRAKE (DISC) CONSTRUCTION

dcf04113398Ot01
4x2 (Except Hi-Rider)

• Large diameter, ventilated disc type front brakes with a 256 mm {10.1 in} diameter and 24 mm {0.94 in}
thickness have been adopted, improving braking force and fade resistance.
,-------------------------------------,
DBR411 ZTB004
Hi-Rider, 4x4
• Two-piston type front disc brake caliper has been adopted, improving braking force.
• Large diameter, ventilated disc type front brakes with a 289 mm {11.4 in} diameter and 28 mm {1.1 in}
thickness have been adopted, improving braking force and fade resistance.
DBR411ZTB005
04-11-6
REAR BRAKE (DRUM) CONSTRUCTION
dcf04112625ot01
• A leading/trailing type rear drum brake, with a 270 mm {10.6 in} (4x2 (except Hi-Rider)) or 295 mm {11.6 in}
(Hi-Rider, 4x4) drum inner diameter and 23.81 mm {0.937 in} wheel cylinder inner diameter, has been
adopted, improving braking force and fade resistance.
• Braking stability is ensured by use of 55 mm {2.16 in} width linings.
• If has an incremental automatic adjustment mechanism of shoe clearance to improve serviceability.
BACKING PLATE
SHOE HOLD PIN
OPERATING LEVER
BRAKE SHOE
BRAKE DRUM
REAR PARKING
BRAKE CABLE
PAWL LEVER
DBR411 ZTB006
04-11-7
REAR BRAKE (DRUM) OPERATION
dcf041126250t02
Automatic Adjustment Mechanism

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

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

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

PARKING BRAKE SYSTEM OUTLINE .. 04-12-1 PARKING BRAKE SYSTEM
STRUCTURAL ViEW ............... 04-12-1
PARKING BRAKE SYSTEM OUTLINE

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• A stick lever type parking brake has been adopted, improving operability.
PARKING BRAKE SYSTEM STRUCTURAL VIEW

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WL-3
PARKING BRAKE PARKING BRAKE

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

ABS OUTLINE [4W-ABS] . ........... 04-13B-1 ABS CONTROL OPERATION
ABS STRUCTURAL VIEW [4W-ABS] .. 04-13B-1 [4W-ABS] ....................... . 04-13B-6
ABS SYSTEM WIRING DIAGRAM ABS WHEEL-SPEED SENSOR AND
[4W-ABS] ....................... 04-13B-2 ABS SENSOR ROTOR FUNCTION
ABS HUlCM CONSTRUCTION [4W-ABS] ....................... . 04-13B-6
[4W-ABS] . ....................... 04-13B-2 ABS WHEEL-SPEED SENSOR AND
ABS HU PART FUNCTION [4W-ABS] .. 04-13B-3 ABS SENSOR ROTOR
ABS HU PART CONSTRUCTION/ CONSTRUCTION/OPERATION
OPERATION [4W-ABS] . ............ 04-13B-3 [4W-ABS] ....................... . 04-13B-6
ABS CM PART FUNCTION [4W-ABS] .. 04-13B-5 G SENSOR FUNCTION [4W-ABS] .... . 04-13B-7
ABS CONTROL OUTLINE [4W-ABS] .. . 04-13B-5 G SENSOR CONSTRUCTION/
OPERATION [4W-ABS] ............ . 04-13B-7
ABS OUTLINE [4W-ABS]

dcf04130000Ot04
• The ASS HU/CM, integrating both the hydraulic unit (HU) and control module (CM), has been adopted,
resulting in size and weight reduction.
• Select-low controlled-4-wheel anti-lock brake system with 4-sensor and 3-channel has been adopted, and has
the following features.
The integrated ASS Hydraulic UniVControl Module (HU/CM) system is compact, lightweight and highly
reliable.
Combined use of the current diagnostic tool and the ASS HU/CM allows the following functions to improve
serviceability:
• 4-digit DTC display
• PID/DATA monitor function
• Active command modes function
ABS STRUCTURAL VIEW [4W-ABS]

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INSTRUMENT CLUSTER
G SENSOR (Hi-Rider, 4x4)
FRONT ABS WHEEL-SPEED

SENSOR
DCF413BTB001
04-138-1
,
ABS SYSTEM WIRING DIAGRAM [4W-ABS]
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ABS/SOL20A
------------------------,
Hi-Rider, 4x4 :
I
I
I
I
1-----------HniG SENSOR :
ABS40A I
1__ - ________________________ ~I
I I
ENGINE SW ENGINE 15A
BRAKE SWITCH
BATTERY ~~N~~~~~~~
BRAKE
LIGHT
ABSWARNING
LIGHT
ABS HU/CM
~~~---or------------rS Q1----------[]
INSTRUMENT CLUSTER
ABSWHEEL-
SPEED SENSOR
D
DCF413BWB001
ABS HUlCM CONSTRUCTION [4W-ABS]

del 04 1343150[08
• A high reliability, reduced size and weight ASS
HU/CM, integrating both the ASS HU and ASS
CM, has been adopted.
DBR413ZTB002
04-138-2
ABS HU PART FUNCTION [4W-ABS]
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• The ABS HU adjusts the fluid pressure to the caliper pistons by controlling (on/off) each solenoid valve and
pump motor according to signals from the ABS CM.
ABS HU PART CONSTRUCTION/OPERATION [4W-ABS]

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Construction
• The integrated ABS HU/CM system controls the ABS. The ABS are an independent front wheel control, rear
axle control, 4-sensor, 3-channel system.
Function of main component Parts

Part name Function
• The solenoid valves control the fluid pressure at individual brake calipers (wheel
cylinders) in accordance with the signal received from the ABS CM.
Inlet solenoid valve, outlet solenoid valve • There are six solenoid valves in total and two solenoid valves in each wheel
(one for retaining pressure and one for reducing pressure) are used. There are
four valves for the front wheel, and the left and right wheels are controlled
separately. There are two valves used to control the rear wheels simultaneously.
• The reservoirs temporarily store the hydraulic pressure which flows from the
Reservoir brake caliper (wheel cylinder) through the outlet solenoid valve during pressure
reduction.
Pump • The pump returns brake fluid from the reservoir to the master cylinder.
Pump motor • Operates the pump according to ABS CM signals.
Hydraulic circuit diagram
MASTER CYLINDER
)(
INLET CHECK VALVE
SOLENOI
VALVE
OUTLET
SOLENOID
VALVE
BRAKE
RESERVOIR RESERVOIR WHEEL
CALIPER
CYLINDER
DBR413ZTB003
04-138-3
Operating
• The ASS HU/CM detects wheel-speed and driving condition based on the ASS wheel-speed sensors, and
outputs on/off electronic signals to the inlet solenoid valves and outlet solenoid valves to control the ASS
control.
• The ASS HUlCM controls ASS by calculating wheel slip from ASS wheel-speed sensor signals, and adjusting
the brake pressure.
Solenoid valve (Inlet) Solenoid valve (Outlet) Pump motor, pump
Normal brake Off (open) Off (close) Stopped
Pressure reduction On (close) On (open) Operating
Pressure retention On (close) Off (close) Stopped
Pressure increase Off (open) Off (close) Stopped
NORMAL BRAKE AND PRESSURE INCREASE
MASTER
CYLINDER "'-r-'-..l....fll
OUTLET SOLENOID
VALVE
RESERVOIR
PRESSURE RETENTION PRESSURE REDUCTION
l' ON
~
p (CLOSE;
ON )(
1 (OPE~
DBR413ZTB004
04-138-4
ANTI LOCK BRAKE SYSTEM [4-WHEEL ANTILOCK BRAKE SYSTEM (4W-ABS)]
ABS CM PART FUNCTION [4W-ABS]
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• The ABS eM detects the vehicle wheel speeds based on the signals from the four ABS wheel- speed sensors.
The eM calculates the rotation condition of each wheel from the relation between the detected vehicle wheel
speed and the estimated (based on the detected speed) vehicle speed from there on. It then accordingly
controls brake fluid pressure to each wheel to prevent lock-up.
Function Table
Function name Contents
ABS control function • Controls brake fluid pressure when braking to maintain directional
stability, ensure steerability and reduce stopping distance.
On-board diagnostic system • Main components of the ABS control system have a self-diagnosis
function. In case a malfunction occurs, warning lights illuminate to alert
the driver, and at the same time a DTC is stored in the ABS HU/CM.
• When a malfunction is determined as a result of on-board diagnosis,
system control is suspended or limited to prevent any dangerous
situation while driving.
ABS CONTROL OUTLINE [4W-ABS]

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• ABS control occurs when wheel slip is determined by the ABS eM (based on the four ABS wheel-speed
sensors). Then, the ABS HU inlet and outlet solenoid valves are operated and brake fluid pressure is controlled
accordingly to prevent wheel lock-up.
• Use of ABS control during emergency braking or on slippery road surfaces allows directional stability to be
maintained, steerability ensured and stopping distance to be reduced.
• The ABS control system has independent front wheel control and unified control (select low) for the rear
wheels.
Note
• Select low control: A control system in which the left and right vehicle wheel speeds are compared and 1!II,:,j
brake fluid pressure is controlled according to the wheel most likely to lock-up. IiII
Block Diagram
ASS HU/CM
CM iI HU
I LF ASS WHEEL-SPEED
SENSOR
I
I
I
I LF CALIPER PISTON
I
I SOLENOID
I RF ASS WHEEL-SPEED
SENSOR
I
I
I
I
VALVE
RF CALIPER PISTON
I
CPU
I
I LR ASS WHEEL-SPEED
SENSOR
I
I
iI
I PUMP
I MOTOR
I RR ASS WHEEL-SPEED
SENSOR
I
I
I
I
LR WHEEL CYLINDER
I RR WHEEL CYLINDER
I
!
t
I G SENSOR (Hi-Rider, 4x4) I
DCF413ZTB012
04-138-5
ABS CONTROL OPERATION [4W-ABS]
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• When the ASS CM determines wheel slip conditions based on the signals from the ASS wheel-speed sensors
during braking, the ASS CM operates the ASS HU inlet and outlet solenoid valves, reducing and maintaining
brake fluid pressure in accordance with the wheel slip factors. Then, when the wheel slip condition has passed,
brake fluid pressure is increased and maintained, ensuring braking with a constantly stable brake force.
Operating Condition Transition Diagram
HIGH
ESTIMATED VEHICLE SPEED
SPEED
WHE~~~:~: _______ ~__
o
TIME
SOLENOID VALVE CONTROL

PRESSURE REDUCTION
PRESSURE MAINTAINED
PRESSURE INCREASE
HIGH
BRAKE FLUID
PRESSURE
o TIME
DBR413ZTB012
ABS WHEEL-SPEED SENSOR AND ABS SENSOR ROTOR FUNCTION [4W-ABS]

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• The ASS wheel-speed sensor, which has a magnetic pick-up, transmits the rotation condition of each wheel to
the ASS HU/CM.
ABS WHEEL-SPEED SENSOR AND ABS SENSOR ROTOR CONSTRUCTION/OPERATION [4W-ABS]

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Construction
• The front ASS wheel-speed sensor is installed on the steering knuckle and the front ASS sensor rotor is
integrated with the front wheel hub (4x2 except Hi-Rider) or drive shaft (Hi-Rider, 4x4).
• The rear ASS wheel-speed sensor is installed on the hub spindle and the rear ASS sensor rotor is integrated
with the rear axle shaft.
ABS WHEEL-SPEED SENSOR
ABS SENSOR ROTOR
POLE PIECE
DBR413ZTB010
04-138-6
Operation
• As the ABS sensor rotor rotates, magnetic flux OUTPUT VOLTAGE WAVEFORM
formed from the permanent magnet varies and +
alternating current is formed with an HIGH SPEED
electromagnetic conductor. Using this alternating
current, rotation speed is expressed as a varying
proportional cycle and from detection of this cycle
V
the CM part of the ABS HU/CM can then detect
the wheel rotation speed. While the structures of
the front and rear ABS wheel-speed sensor differ,
LOW SPEED
the operation is the same.
DBR413ZTB011
G SENSOR FUNCTION [4W-ABS]

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Note
• Because the Hi-Rider vehicle is based on the 4x4 vehicle, the 4x4 vehicle ABS system has been adopted.
Therefore, the G-sensor, which is generally installed to 4x4 vehicles only, is installed to the Hi-Rider.
• Because the 4x4 vehicle ABS system has been adopted on the Hi-Rider, the ABS is controlled in the
same way as the 4x4 vehicle.
• In the Hi-Rider and 4x4 vehicle, the G sensor detects and calculates the vehicle G force (acceleration and
deceleration G force), and outputs the change in voltage to the ABS HUiCM.
G SENSOR CONSTRUCTION/OPERATION [4W-ABS]

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III
• The G sensor is installed under the RH front seat and detects vehicle movement during a brake lockup event
that is transferred to other wheels through the powertrain, and transmits the signal to the ABS HU/CM.
• The drive train of 4x4 vehicles delivers driving force to all four wheels, and due to this interlocking, the speed of
all wheels during braking is the same. When driving on road surfaces with especially low m (friction coefficient), 1:4
it is difficult to estimate the vehicle speed based on the wheel speed, and ABS braking becomes unreliable.
(For 4x2 vehicles, the front and rear wheels are independent, so it is possible to accurately estimate the vehicle
speed by measuring the difference between the rotation speeds of the front and rear tires.) A G sensor is
installed to overcome this situation. When braking, the change in G-force is detected, and the road surface m is
judged (low m, high m), enabling a correction of the vehicle speed estimation.
• The output characteristics are based on 2.5 V with the vehicle in a stopped or driven with constant speed, and
the subsequent fluctuation is depending on the situation whereby the G force occurs.
EXTERNAL VIEW OUTPUT VOLTAGE

CHARACTERISTIC
(V)
VEHICLE 2.5
FORWARD
-1.5 o +1.5 (G)

DECELERATION
DBR413ZTB006
04-138-7
.,
TRANSMISSION! I RANSAXLE
OUTLINE ................. OS-OO MANUAL TRANSMISSION

CLUTCH .................. OS-10 [R1SM-D] ................ OS-11 A
MANUAL TRANSMISSION
[S1SM-D, S1SMX-D] ........ OS-11 B
05-00 OUTLINE
TRANSMISSIONfTRANSAXLE TRANSMISSIONfTRANSAXLE
ABBREVIATIONS ................. 05-00-1 FEATURES ....................... 05-00-1
TRANSMISSIONfTRANSAXLE
SPECIFICATIONS •••....•........• 05-00-1
TRANSMISSIONfTRANSAXLE ABBREVIATIONS
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MT Manual Transmission
1GR First Gear
2GR Second Gear
5GR Fifth Gear
TRANSMISSIONfTRANSAXLE FEATURES
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CLUTCH
Reduced noise and
• Dual-mass flywheel adopted. (S15M-D, S15MX-D)
vibration
Improved durability • Clutch cover with wear assurance function adopted.
Improved startability • One-way valve that fits inside a clutch master cylinder adopted.
MT [R15M-D]
Improved operability • A double cone synchronizer mechanism has been adopted for 2nd gear.
Improved reliability • A double engagement prevention mechanism (interlock mechanism) has been adopted.
Mis-shift prevention • A stopper pin-type reverse lock-out mechanism has been adopted.
MT [S15M-D, S15MX-D]
• A linked, triple cone synchronizer mechanism has been adopted for 1st and 2nd gears.
Improved operability
• A linked, double cone synchronizer mechanism has been adopted for 3rd gear.
Improved reliability • A double engagement prevention mechanism (interlock mechanism) has been adopted.
Mis-shift prevention • A cam-type reverse lock-out mechanism has been adopted.
TRANSMISSIONfTRANSAXLE SPECIFICATIONS
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Clutch
Item Specifications
Manual transmission type R15M-D S15M-D, S15MX-D
Clutch control Hydraulic
Spring type Diaphragm
Clutch cover
Set load (N {kgf, Ibf}) 5,290 {539, 1, 189} 10,100 {1 ,030, 2,271}
Outer diameter (mm {in}) 240 {9A5} 250 {9.84}
Clutch disc
Inner diameter (mm {in}) 160 {6.30} 155 {6.10}
Type Suspended
Clutch pedal Pedal ratio 6.0 5.2
Full stroke (mm {in}) 152 {5.984}
Clutch master cylinder inner diameter (mm {in}) 15.87 {0.6248}
05-00-1
OUTLINE
Item Specifications
Manual transmission type R15M-D I
S15M-D, S15MX-D
Clutch release cylinder inner diameter (mm {in}) 19.05 {0.7500} I 22.23 {0.8752}
Clutch fluid type SAE J1703, FMVSS 116 00T-3
Manual Transmission [R15M-D]

Item Specifications
Transmission type R15M-D
Transmission control Floor-shift
Shift assist Synchromesh
1GR 4.250
2GR 2.356
3GR 1.428
Gear ratio
4GR 1.000
5GR 0.827
Reverse 3.656
Grade API service GL-4 or GL-5
Viscosity
IAll season SAE 75W-90
Oil IAbove 10°C {50°F} SAE 80W-90
Capacity
(L {US qt, Imp qt}) 2.8 {3.0, 2.5}
(approx. quantity)
Manual Transmission [S15M-D, S15MX-D]

Item Specifications
Transmission type S15M-D, S15MX-D
Shift assist Synchromesh
1GR 3.905
2GR 2.248
3GR 1.491
Gear ratio
4GR 1.000
5GR 0.800
Reverse 3.391
Type Mercon® Multi-purpose AFT XT-2-QOX
Oil Capacity
(L {US qt, Imp qt}) 3.55 {3.75, 3.12}
(approx. quantity)
05-00-2
TRANSMISSION/I RANSAXLE
o UTLI NE . . . . . . . . . . . . . . . . . OS-OO AUTOMATIC TRANSMISSION

ON-BOARD [SRSSS] .................. OS-13
DIAGNOSTIC[SRSSS] ...... OS-02 AUTOMATIC TRANSMISSION
SHIFT MECHANISM ........ OS-14
05-00 OUTLINE
TRANSMISSIONrrRANSAXLE TRANSMISSIONrrRANSAXLE
FEATURES [5R55S] ............... 05-00-1 SPECIFICATIONS [5R55S] ......... . 05-00-1
TRANSMISSIONrrRANSAXLE FEATURES [5R55S]

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Improved marketability • Five-speed 5R55S automatic transmission has been adopted.

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

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

ON-BOARD DIAGNOSTIC (OBD) MALFUNCTION INDICATION
SYSTEM OUTLINE [5R55S] . ........ 05-02-1 FUNCTION [5R55S] ............... . 05-02-3
ON-BOARD DIAGNOSTIC (OBD) FAIL-SAFE FUNCTION [5R55S] ...... . 05-02-3
SYSTEM BLOCK DIAGRAM PARAMETER IDENTIFICATION (PID)
[5R55S] . . . . . . . . . . . . . . . . . . . . . . . . . 05-02-1 DATA MONITORING FUNCTION
MALFUNCTION DETECTION [5R55S] . ......................... 05-02-4
FUNCTION [5R55S] ............... 05-02-2 SIMULATION FUNCTION [5R55S] ..... 05-02-4
MEMORY FUNCTION [5R55S] ........ 05-02-3 DLC-2 OUTLINE [5R55S] . ........... . 05-02-5
ON-BOARD DIAGNOSTIC (OBD) SYSTEM OUTLINE [5R55S]

id0502c11 001 00
• The OBD system has the following functions:

Malfunction detection function: Detects malfunctions of the input/output devices and system components of
the AT.
Fail-safe function: Fixes the output device function and input value of the sensors/switches to ensure
minimum vehicle driveability when a malfunction is detected.
Memory function: Stores the DTC when a malfunction is detected.
PID data monitored function: Monitors the input/output signal and calculated value of the TCM, and sends
the monitoring data to the IDS/PDS.
Simulation function: Allows override operation of simulation items for input/output system parts preset in the
TCM.
ON-BOARD DIAGNOSTIC (OBD) SYSTEM BLOCK DIAGRAM [5R55S]

id0502c1100200
TCM
INSTRUMENT CLUSTER
--------------------------------------1
OBD SYSTEM
1
1 OlD OFF
1 INDICATOR LIGHT
MALFUNCTION
I
~
INDICATION FUNCTION CAN MIL
I-~ H--I1
PCM
MEMORY _I 1
FUNCTION 1
1
!=
-I
l_~ j CAN
SERIAL COMMUNICATION
r--- 1
CAN
IIDS/PDS
I
MALFUNCTION PID DATA
SIMULATION
DETECTION MONITORING
FUNCTION
FUNCTION FUNCTION
t L;"~ ~~
I FAIL-SAFE I
---V---
FUNCTION
- ----- - -------- - -----
V V
PCM
CA~ -
~ OUTPUT
TRANSMISSION CONTROL SYSTEM
-
-V PARTS
~
INPUT r--
PARTS
r--
arnffn00000333
05-02-1
MALFUNCTION DETECTION FUNCTION [SRSSS]
id0502c1100300
Malfunction Detection Function
• In the malfunction detection function, the TCM detects malfunctions in the automatic transmission while driving.
• When vehicle driving conditions correspond with a preset malfunction detection condition, the TCM determines
that the automatic transmission has a malfunction and stores the corresponding DTC.
• When a malfunction is detected, stored DTCs can be retrieved using the IDS/PDS connected to the DLC-2.
DTC Table
DTC No. Condition
P0657 Solenoid valve power supply circuit open
P0658 Solenoid valve power supply circuit voltage low
P0705 Digital transmission range (TR) sensor circuit malfunction (invalid bit pattern)
P0708 Digital transmission range (TR) sensor circuit malfunction (TR3A circuit open)
P0711 Transmission fluid temperature (TFT) sensor malfunction (ATF temperature no change)
P0712 Transmission fluid temperature (TFT) sensor circuit malfunction (short to ground)
P0713 Transmission fluid temperature (TFT) sensor circuit malfunction (open circuit)
P0715 Turbine shaft speed (TSS) sensor malfunction
P0717 Turbine shaft speed (TSS) sensor signal is not input
P0718 Turbine shaft speed (TSS) sensor signal noise
P0720 Output shaft speed (OSS) sensor malfunction
P0721 Output shaft speed (OSS) sensor signal noise
P0722 Output shaft speed (OSS) sensor signal is not input
P0731 Gear 1 incorrect
P0740 Torque converter clutch (TCC) control solenoid circuit malfunction (open circuit)
P0741 Torque converter clutch (TCC) control solenoid circuit malfunction (stuck off)
P0742 Torque converter clutch (TCC) control solenoid circuit malfunction (stuck on)
P0743 Torque converter clutch (TCC) control solenoid circuit malfunction (open or short circuit)
P0744 Torque converter clutch (TCC) control solenoid circuit malfunction (short to power)
P0745 Pressure control solenoid A malfunction (low pressure)
P0748 Pressure control solenoid A circuit malfunction (non-operati0n)
P0750 Shift solenoid A circuit malfunction (open or short circuit)
P0753 Shift solenoid A circuit malfunction (open or short circuit)
P0755 Shift solenoid B circuit malfunction (open or short circuit)
P0757 Shift solenoid B malfunction (stuck on)
P0758 Shift solenoid B circuit malfunction (open or short circuit)
P0760 Shift solenoid C circuit malfunction (open or short circuit)
P0762 Shift solenoid C malfunction (stuck on)
P0763 Shift solenoid C circuit malfunction (open or short circuit)
P0765 Shift solenoid D circuit malfunction (open or short circuit)
P0768 Shift solenoid D circuit malfunction (open or short circuit)
P0775 Pressure control solenoid B malfunction (low pressure)
P0778 Pressure control solenoid B circuit malfunction (non-operation)
P0791 Intermediate shaft speed (ISS) sensor malfunction
P0794 Intermediate shaft speed (ISS) sensor signal noise
P0795 Pressure control solenoid C malfunction (low pressure)
P0798 Pressure control solenoid C circuit malfunction (non-operation)
P0960 Pressure control solenoid A circuit malfunction (open circuit)
P0962 Pressure control solenoid A circuit malfunction (short to ground)
P0963 Pressure control solenoid A circuit malfunction (short to power supply)
P0964 Pressure control solenoid B circuit malfunction (open circuit)
P0966 Pressure control solenoid B circuit malfunction (short to ground)
P0967 Pressure control solenoid B circuit malfunction (short to power supply)
05-02-2
ON-BOARD DIAGNOSTIC [SRSSS]
OTC No. Condition

P0968 Pressure control solenoid C circuit malfunction (open circuit)
P0970 Pressure control solenoid C circuit malfunction (short to ground)
P0971 Pressure control solenoid C circuit malfunction (short to power supply)
P1635 Tire/axle ratio out of acceptable range
P1700 Transmission indeterminate malfunction
P1702 Digital transmission range (TR) sensor circuit intermittent
P1704 Digital transmission range (TR) sensor circuit not indicating P or N position during on-board diagnostic
P1705 Digital transmission range (TR) sensor circuit not indicating P or N position during on-board diagnostic
P1711 ATF temperature out of on-board diagnostic range
P1780 0/0 OFF switch circuit malfunction (open or short circuit)
P1783 ATF overheating
U0100 Communication error to PCM
U0294 Communication error to PCM
MEMORY FUNCTION [SRSSS]

id0502c11 00400
• The memory function stores malfunction information detected in the malfunction detection function. Once
malfunction information is stored, the memory will not be cleared even when the engine switch is turned off
(LOCK position) or the malfunction is repaired.
• The stored memory (malfunction information) can be cleared using the IDS/PDS, or by disconnecting the
negative battery cable.
MALFUNCTION INDICATION FUNCTION [SRSSS]

id0502c11 00500
• The malfunction indication function illuminates the MIL or flashing the OlD OFF indicator light when the
malfunction detection function determines that there is a malfunction.
FAIL-SAFE FUNCTION [SRSSS]

id0502c11 00600
• In the fail-safe function, minimum vehicle driveability is obtained by changing the signals that are determined to
be irregular by the malfunction detection function to the preset values, and limiting TCM control.
05-02-3
,
PARAMETER IDENTIFICATION (PID) DATA MONITORING FUNCTION [SRSSS]
id0502c11 00700
• The PID mode allows access to certain data values, analog and digital input and output, calculations and
system state information.
PID/DATA MONITOR AND RECORD function table
Unit!
Monitor item Definition TCM terminal
Condition
BPP Brake switch on/off N/A
FIRM_ST Firm shaft control (FSC) status requested 0/1 N/A
GEAR Calculated gear range in TCM 1/2/3/4/5 N/A
GEAR_OSC PID used to command gear changes during Simulation Function 1/2/3/4/5 N/A
ISS ISS sensor rpm AM,AS
ass ass sensor rpm AD,AG
PCA Pressure control solenoid A pis I,CK
PCB Pressure control solenoid B pis J, CK
PCC Pressure control solenoid C pis M,CK
RPM Engine speed rpm N/A
SSA Shift solenoid A on/off B,CK
SSB Shift solenoid B on/off C,CK
SSC Shift solenoid C on/off F, CK
SSD Shift solenoid 0 on/off D,CK
TCC TCC control solenoid % A,CK
TCCRAT Torque converter speed ratio ratio N/A
TFT ATF temperature °c, OF AY, BH
TR_D Digital TR sensor signal AX, BU, BY, CA
TR_V Digital TR sensor signal voltage V AX, BU, BY, CA
TR1 TR1 switch 0/1 BY
TR2 TR2 switch 0/1 BU
TR3A TR3 switch 0/1 AX
TR4 TR4 switch 0/1 CA
TSS TSS sensor rpm AH,AP
VSS Vehicle speed mph AD,AG
SIMULATION FUNCTION [SRSSS]

id0502c11 00800
• By using the IDS/PDS, simulation items for input/output parts preset in the TCM can be optionally selected and
operated regardless of TCM control conditions.
Simulation item table
Simulation item Applicable component Unit TCM terminal
PCA Pressure control solenoid A pis I,CK
SSA Shift solenoid A on/off B, CK
SSD Shift solenoid 0 on/off D,CK
TCC TCC control solenoid 0/0 A,CK
05-02-4
DLC-2 OUTLINE [5R55S]
id0502c11 00900
• A connector (DLC-2) conforming to International Organization for Standardization (ISO) standards has been
adopted .
• The shape and terminal arrangement as stipulated by the ISO 15031-3 (SAE J1962) international standard has
been adopted for this connector. The connector has a 16-pin construction that includes the B+, CAN_H,
CAN_L, GND1, GND2 and KLN terminals.
DLC-2
atraan00000380
Terminal Function
B+ Battery power supply terminal
CAN_L Serial communication terminal (Lo)
CAN_H Serial communication terminal (Hi)
GND1 Body ground terminal
GND2 Serial communication ground terminal
KLN Serial communication terminal (Malfunction diagnosis use)
05-02-5
CLUTCH
05-10 CLUTCH
CLUTCH STRUCTURAL ViEW ........ 05-10-1 CLUTCH COVER OUTLINE
CLUTCH MASTER CYLINDER [S15M-D, S15MX-D] . .............. . 05-10-2
CONSTRUCTION ................. 05-10-2 DUAL-MASS FLYWHEEL FUNCTION
CLUTCH RELEASE CYLINDER [S15M-D, S15MX-D] ............... . 05-10-3
construction . .................... 05-10-2
CLUTCH STRUCTURAL VIEW

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

DCG510ZT8002
Vehicles with clutch damper

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

dcf05100000Dt04
• The clutch release cylinder consists of a return
BLEEDER SCREW
spring, piston, push rod and a bleeder screw for
bleeding air.
• Due to spring pressure maintaining play between
the push rod end and the release fork at zero, an
automatic adjusting, maintenance-free design
has been achieved.
RETURN SPRING PISTON

DCG510ZT8004
CLUTCH COVER OUTLINE [S15M-D, S15MX-D]

dcf05100000Dt05
• The wear assurance function of the clutch cover maintains the set load of the clutch cover unchanged even as
the clutch disc becomes worn, thereby extending disc life.
05-10-2
CLUTCH
DUAL-MASS FLYWHEEL FUNCTION [S15M-D, S15MX-D]
dcf05100000Ot06
• The dual-mass flywheel has separated primary and secondary flywheel, and a torsional damper that is located
inside the flywheel. Due to this structure, the transmission main drive gear shaft rotation can be stabilized,
decreasing noise inside the transmission (gear teeth rattling) created by engine speed fluctuation, and thereby
greatly reducing vehicle booming noise also.
TORSIONAL DAMPER
PRIMARY FLYWHEEL SECONDARY FLYWHEEL
DCG510ZTB005
05-10-3
MANUAL TRANSMISSION [S1SM-D, S1SMX-D]
05-118 MANUAL TRANSMISSION [S15M-D, S15MX-D]

MANUAL TRANSMISSION OUTLINE DOU8LEconeSYNCHRON~ER
[S15M-D, S15MX-D] ...........•... 05-118-1 MECHANISM OUTLINE
MANUAL TRANSMISSION [S15M-D, S15MX-D] .••.•.....•..... 05-118-7
CROSS-SECTIONAL VIEW DOU8LECONESYNCHRON~ER
[S15M-D, S15MX-D] ........•..••.. 05-118-2 MECHANISM CONSTRUCTION/
MANUAL TRANSMISSION POWER OPERATION [S15M-D, S15MX-D] ..... 05-118-7
FLOW [S15M-D, S15MX-D] ..•..•.... 05-118-3 SHIFT INTERLOCK MECHANISM
SHIFT MECHANISM OUTLINE FUNCTION [S15M-D, S15MX-D] ...... 05-118-7
[S15M-D, S15MX-D] •.•....•.•...•. 05-118-4 SHIFT INTERLOCK MECHANISM
TRIPLE CONE SYNCHRONIZER OPERATION [S15M-D, S15MX-D] ..... 05-118-7
MECHANISM STRUCTURE REVERSE LOCKOUT MECHANISM
[S15M-D, S15MX-D] .•............. 05-118-5 FUNCTION [S15M-D, S15MX-D] ...... 05-118-8
TRIPLE CONE SYNCHRONIZER REVERSE LOCKOUT MECHANISM
MECHANISM OPERATION CONSTRUCTION/OPERATION
[S15M-D, S15MX-D] ........•..••.. 05-118-5 [S15M-D, S15MX-D] .......•........ 05-118-8
MANUAL TRANSMISSION OUTLINE [S15M-D, S15MX-D]

dcf051100000133
• A linked, triple cone synchronizer mechanism has been adopted for 1st and 2nd gears.
• A cam-type reverse lockout mechanism has been adopted.
05-118-1
MANUAL TRANSMISSION CROSS-SECTIONAL VIEW [S15M-D, S15MX-D]
dcf0511 00000134
S1SM-D
2ND GEAR
S1SMX-D
r--------------------I
I
COUNTER REVERSE GEAR REVERSE IDLER GEAR
DCG5118T8001
05-118-2
MANUAL TRANSMISSION POWER FLOW [S15M-D, S15MX-D]
dcf0511 00000135
DCG5118T8002
05-118-3
MANUAL TRANSMISSION [S15M-O, S15MX-O]
SHIFT MECHANISM OUTLINE [S15M-D, S15MX-D]
dcf05110000ot36
• To realize assured shift feel, the shift link mechanism has been integrated.
SHIFT LINK UNIT
SEC: A-A
- "'..--=,: =-------------------------------': :. :'~,.---_ ..

_______________ : __________ 3.A __ d> -
DCG5118T8003
05-118-4
TRIPLE CONE SYNCHRONIZER MECHANISM STRUCTURE [S1SM-D, S1SMX-D]
dcf051100000t37
Features
• A triple cone synchronizer mechanism is used for the 1st and 2nd gears.
• The triple cone synchronizer mechanism is a compact device capable of heavy duty meshing.
• The synchro mechanism reduces meshing time and improves operation.
• The triple cone synchro mechanism includes a synchronizer ring, a double cone, and an inner cone.
Structure
Structural view
DCG5118T8004
TRIPLE CONE SYNCHRONIZER MECHANISM OPERATION [S1SM-D, S1SMX-D]

dcf05110000Ot38
1. When the hub sleeve moves to the left (in the

direction of the arrow), the synchronizer key SYNCHRONIZER CLUTCH HUB SLEEVE
presses against the synchronizer ring. RING
INNER
E5U511 8S501 0
05-118-5
2. As the hub sleeve continues moving to the left,
the key causes friction between the synchronizer
ring, double cone, and inner cone and 2nd gear.
The synchronizer ring turns only the distance that
the key groove gap allows, aligning the teeth of SYNCHRONIZER RING
the hub sleeve and the synchronizer ring. As the
hub sleeve continues moving, the friction I SYNCHRONIZER KEY
between the cones becomes greater, and the
difference between the rotational speeds of the
synchronizer ring, inner cone, and double cone
(unified with the gear) gradually disappears.
DCG511 BTB005
3. The hub sleeve then moves up onto the

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

of the gear to complete shifting.
SYNCHRO SPLINE
~
DCG511BTB015
05-118-6
DOUBLE cone SYNCHRONIZER MECHANISM OUTLINE [S15M-D, S15MX-D]
dcf05110000ot44
• The double cone synchronizer mechanism consists of a synchronizer ring, double cone, and inner cone the
same as a triple cone synchronizer mechanism.
DOUBLE CONE SYNCHRONIZER MECHANISM CONSTRUCTION/OPERATION [S15M-D, S15MX-D]

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

dcf05110000Ot39
• This provides reliable double-engagement prevention.
SHIFT INTERLOCK MECHANISM OPERATION [S15M-D, S15MX-D]

dcf05110000ot40
Structure
• During shifting, the shift rods, except for the one in operation, are locked in the neutral position by the interlock
pins.
Operation
Neutral
• Because no shift rod is operated, the interlock
1ST/2ND SHIFT ROD
pins are seated in the grooves.
/
7
3RD/4TH SHIFT ROD
INTERLOCK PINS
""
5TH/REVERSE SHIFT ROD
1stl2nd shifting
• Movement of the 1stl2nd shift rod forces interlock
1ST/2ND SHIFT ROD
pin A out of the 1stl2nd shift rod groove, and locks
the 3rd/4th shift rod. Pin B, forced by pin A,
pushes out pin C to lock the 5th/Reverse shift rod. 3RD/4TH SHIFT ROD
.
\...--....J.l..------m ..
~-----

DCG511BTB011
05-118-7
3rd/4th shifting
• Movement of the 3rd/4th shift rod forces out pins
1ST/2ND SHIFT ROD
A and C, and locks the 1st/2nd and 5th/Reverse
shift rods. Pin B does not affect the other pins or /
7
shift rods during 3rd/4th shifting. 3RD/4TH SHIFT ROD
t
n-----7~~i--------
c
""
DCG511BTB012
5th/Reverse shifting
• When performing 5th/Reverse shifting, the
1ST/2ND SHIFT ROD
interlock pins function the same way as in 1st/2nd
shifting, except the pin movement order is in
reverse, and the 3rd/4th and 1st/2nd shift rods are 3RD/4TH SHIFT ROD
locked.

DCG511 BTB013
REVERSE LOCKOUT MECHANISM FUNCTION [S15M-D, S15MX-D]

dcf051117570to9
• The reverse lockout mechanism prevents the driver from accidentally shifting into reverse gear when
downshifting from 5th to 4th gear.
REVERSE LOCKOUT MECHANISM CONSTRUCTION/OPERATION [S15M-D, S15MX-D]

dcf05111757Ot10
• A cam-type reverse lockout mechanism is adopted to ensure reliability.

• A cam, which is installed to the shift guide plate in the shift control case, restricts the selector movement to
prevent the driver from miss shifting.
• When shifting into reverse, by shifting the selector back into the neutral position once and then shifting to the
5th/reverse direction, the selector pushes the cam outward to release the shifting restriction, and shifting into
reverse is made possible.
05-118-8
S15M-D
SHIFTING DIRECTLY FROM SHIFTING INTO REVERSE AFTER

5TH INTO REVERSE SHIFTING INTO NEUTRAL
REVERSE
l~J1lllj NEUTRAL
5TH
SELECTOR SELECTOR
05-118-9
S1SMX-O
SHIFTING DIRECTLY FROM 5TH INTO REVERSE SHIFTING INTO REVERSE AFTER SHIFTING INTO NEUTRAL
RESTRICTS MOVEMENT REVERSE i'
REVERSE 4TH
t NEUTRAL -I--+--___~ NEUTRAL
5TH 3RD
5TH
SELECTOR SELECTOR
DCG5118T8014
05-118-10
AUTOMATIC TRANSMISSION [5R55S]
05-13 AUTOMATIC TRANSMISSION [5R55S]

AUTOMATIC TRANSMISSION FLUID FILTER
OUTLINE [5R55S] . ................ 05-13-1 CONSTRUCTION [5R55S] . ......... . 05-13-28
AUTOMATIC TRANSMISSION CONTROL VALVE BODY
CROSS-SECTIONAL VIEW OUTLINE [5R55S] ................ . 05-13-29
[5R55S] ......................... 05-13-2 PRESSURE CONTROL
AUTOMATIC TRANSMISSION HYDRAULIC CIRCUITS
CONTROL SYSTEM CONSTRUCTION [5R55S] . ......... . 05-13-32
WIRING DIAGRAM [5R55S] ......... 05-13-3 SHIFT SOLENOID
EC-AT OPERATION CHART HYDRAULIC CIRCUITS
IDENTIFICATION TAG OUTLINE TORQUE CONVERTER/LUBE
[5R55S] ......................... 05-13-5 HYDRAULIC CIRCUITS
RANGE SELECTION [5R55S] ........ 05-13-6 CONSTRUCTION [5R55S] . ......... . 05-13-42
SHIFT PATTERNS [5R55S] ... ........ 05-13-7 APPLY COMPONENT
POWERFLOW OPERATION HYDRAULIC CIRCUITS
TORQUE CONVERTER OUTLINE ELECTRONIC CONTROL
[5R55S] ......................... 05-13-16 SYSTEM OUTLINE [5R55S] ........ . 05-13-55
PLANETARY GEARSETS ELECTRONIC CONTROL
CONSTRUCTION [5R55S] .......... 05-13-17 SYSTEM BLOCK DIAGRAM
APPLY COMPONENTS [5R55S] . ......................... 05-13-55
CONSTRUCTION [5R55S] .......... 05-13-18 ELECTRONIC CONTROL
PARKING LOCK SYSTEM STRUCTURE [5R55S] ..... . 05-13-56
CONSTRUCTION [5R55S] .......... 05-13-25 OIL COOLER CONSTRUCTION
LUBRICATION [5R55S] ............. 05-13-26 [5R55S] . ......................... 05-13-58
FLUID PUMP
CONSTRUCTION [5R55S] .......... 05-13-27
AUTOMATIC TRANSMISSION OUTLINE [5R55S]

• This transmission has the following features:
Five forward speeds
Electronic shift, pressure and torque
converter clutch controls
Three compound planetary gearsets
- Three bands (overdrive, intermediate, low/
reverse)
- Three multi-plate clutches (coast, direct,
forward)
- Two one-way clutches (Overdrive, low/
reverse)
• All hydraulic functions are directed by electronic
solenoids. The solenoids control:
Static engagement feel.
Shift feel.
Shift scheduling.
Modulated torque converter clutch (TCC) applications.
Engine braking utilizing the coast clutch and band.
Manual 1st and 2nd timing.
Reverse inhibit timing.
05-13-1
AUTOMATIC TRANSMISSION CROSS-SECTIONAL VIEW [5R55S]
id0513c1250400
TSS SENSOR ISS SENSOR LOW/REVERSE

FLUID ONE-WAY CLUTCH
PUMP
OSS SENSOR
LOW/REVERSE
OVERDRIVE BRAKE
BRAKE
OVERDRIVE ONE- INTERMEDIATE CONTROL VALVE

WAY CLUTCH BRAKE BODY
arnffn00000345
05-13-2
AUTOMATIC TRANSMISSION CONTROL SYSTEM WIRING DIAGRAM [5R55S]
id0513c1250900
IG1 B+ B+
TCM
AT RELAY
TCC CONTROL SOLENOID

OTHER
MODULE
SHIFT SOLENOID A
SHIFT SOLENOID B
4x4
SHIFT SOLENOID C
CONTROL
MODULE
SHIFT SOLENOID D
IG1
PRESSURE CONTROL SOLENOID A
PRESSURE CONTROL SOLENOID B

J~----I
PRESSURE CONTROL SOLENOID C

MI------I
INSTRUMENT
CLUSTER
OSS SENSOR
ISS SENSOR
TSS SENSOR
arnffn00000405
05-13-3
AUTOMATIC TRANSMISSION [SRSSS]
EC-AT OPERATION CHART [5R55S]
id0513c1251 000
Solenoid Operation Chart
Pressure Pressure Pressure
Gear Shift Shift Shift Shift
Selector position control control control
position solenoid A solenoid 8 solenoid C solenoid D
solenoid A solenoid 8 solenoid C
p - - On Off Off On Low High/Low Low
R - Reverse On Off Off On Low/High Low High
N - - On Off Off On Low High/Low Low
1GR On Off Off On High High/Low Low
2GR On Off On On Low/High High Low
Normal 3GR On On Off On High· Low/High Low
4GR Off Off Off On High Low/High High
0 5GR Off Off On On High High/Low High
1GR On Off Off On High High/Low Low
2GR On Off On On Low/High High Low
0/0 OFF
3GR On On Off On High Low/High Low
4GR Off Off Off Off Low/High High High
3 - 3GR On On Off Off High Low High/Low
2 - 2GR On Off On Off High Low High/Low
1 - 1GR On Off Off Off High Low High/Low
Band and Clutch Application Chart A

Gear Overdrive Intermediate Low/reverse Forward
Selector position Direct clutch .Coast clutch
position band band band clutch
p - - - - - - - -
R - Reverse - - A - A Ac
N - - - - - - - -
1GR - - - A - -
2GR A - - A - -
Normal 3GR - A - A - -
4GR - - - A A -
0 5GR A - - A A -
1GR - - - A - -
2GR A - - A - -
0/0 OFF
3GR - - - A - -
4GR - - - A A Ac
3 - 3GR Ac - A - Ac
2 - 2GR A - Ac A - -
1 - 1GR - - Ac A - Ac
A : Applied
Ac : Applied to carry coast torque.
- : N/A
05-13-4
Band and Clutch Application Chart B
Gear Direct one-way clutch Low/reverse one-way clutch
Selector position Engine braking
position Drive Coast Drive Coast
p - - - - - - -
R - Reverse H NE NE NE No
N - - - - - - -
1GR H NE H NE No
2GR OR OR H NE No
Normal 3GR H NE OR OR No
4GR H NE OR OR No
D 5GR OR OR OR OR Yes
1GR H NE H NE Yes
2GR OR OR H NE Yes
OlD OFF
3GR H NE OR OR Yes
4GR H NE OR OR Yes
3 - 3GR H NE OR OR Yes
2 - 2GR OR OR H NE Yes
1 - 1GR H NE H NE Yes
H : Hold
NE: No effect
OR: Overrunning
- : N/A
IDENTIFICATION TAG OUTLINE [SRSSS]

id0513c1323600
• All vehicles are equipped with a vehicle

certification label, located on the driver side door
lock post. Refer to the code in the space marked TRANSMISSION BAR CODE 1 ITEM TRANSMISSION
TR. For model, service ID level or build date PART NUMBER DESCRIPTION PLANT MODEL CODE
PART 1
information, refer to the transmission service ID
tag located on the transmission case.
6M3P 7000 AB
1lllllllllllmlll~llmlllllllllllllllll BL2 TRANSMISSION
PLANT MODEL
o 404 CODE PART 2
BAR CODE 2
1111111111111111111111111111111111111111111111111111111111111111
A6G12 020204 040508
ASSEMBLY PLANT TRANSMISSION BUILD TRANSMISSION

LINE SHIFT DATE (DD MM YY) SERIAL NUMBER
arnffn00000347
05-13-5
RANGE SELECTION [SRSSS]
id0513c1323700
• The transmission has 7 range positions: P, R, N,

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

id0513c1323800
Upshifts
• Transmission upshifting is controlled by the TCM. The TCM receives inputs from various engine or vehicle
sensors and driver demands to control shift scheduling, shift feel and torque converter clutch (TCC) operation.
• The TCM has an adaptive learn strategy to electronically control the transmission which will automatically
adjust the shift feel.
• Even if the battery is disconnected or a new battery installed, transmission operating parameters are kept. The
TCM must relearn these parameters.
Downshifts
• Under certain conditions the transmission will downshift automatically to a lower gear range (without moving
the range selector lever).
• There are 3 categories of automatic downshifts: coastdown, torque demand and forced or kickdown shifts.
Coastdown
• The coastdown downshift occurs when the vehicle is coasting down to a stop.
Torque Demand
• The torque demand downshift occurs (automatically) during part throttle acceleration when the demand for
torque is greater than the engine can provide at that gear ratio.
• If applied, the transmission will disengage the TCC to provide added acceleration.
Kickdown
• For maximum acceleration, the driver can force a downshift by pressing the accelerator pedal to the floor.
• A forced downshift into a lower gear is possible below calibrated speeds.
• Specifications for downshift speeds are subject to variations due to tire size and engine and transmission
calibration requirements.
05-13-7
1 I
POWERFLOW OPERATION [5R55S]
id0513c1320600
P or N Position
Apply component operation
• Overdrive one-way clutch holding
• Output shaft stationary with the parking pawl holding the parking gear (transmission shifter in P position)
Planetary gearset operation
• Overdrive gearset indirect
• Forward/Reverse gearset driving member:
- None
• Forward/Reverse gearset driven member:
- None
• Forward/Reverse gearset held member:
- None
• Forward/Reverse gearset member also rotating:
- None
P OR N POSITION
OVERDRIVE ONE-WAY
CLUTCH HOLDING
R Position
• Overdrive one-way clutch holding (drive)
• Direct clutch applied
• Low/reverse band applied
- Forward/reverse sun gear
- Forward planetary carrier component and reverse ring gear
- Reverse planetary carrier component .
- Forward ring gear
05-13-8
R POSITION
OVERDRIVE ONE-WAY CLUTCH

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

LOW/REVERSE ONE-WAY
CLUTCH (DRIVE ONLY)
o
arnffn00000389
05-13-9
-, I
D Range 2GR
• Overdrive band applied
• Overdrive gearset in overdrive
- Forward ring gear
D RANGE 2GR
OVERDRIVE BAND
APPLIED
LOW/REVERSE ONE-WAY CLUTCH

arnifn00000390
D Range 3GR
• Intermediate band applied
- Forward ring gear
05-13-10
ORANGE 3GR
INTERMEDIATE BAND
APPLIED
FORWARD CLUTCH
OVERDRIVE ONE-WAY APPLIED
CLUTCH HOLDING
(DRIVE ONLY)
D Range 4GR
- Forward ring gear
- None
ORANGE 4GR
DIRECT CLUTCH
APPLIED
FORWARD CLUTCH
CLUTCH HOLDING
(DRIVE ONLY)
05-13-11
D Range 5GR
- Forward ring gear
- None
D RANGE 5GR
DIRECT CLUTCH
APPLIED
OVERDRIVE BAND
FORWARD CLUTCH
APPLIED
APPLIED
arnffn00000393
D Range 4GR, OlD OFF Mode (Manual 4GR)

• Coast clutch applied
- Forward ring gear
- None
05-13-12
ORANGE 4GR, % OFF MODE (MANUAL 4GR)
DIRECT CLUTCH
APPLIED
COAST CLUTCH
APPLIED
FORWARD CLUTCH
CLUTCH HOLDING
(DRIVE ONLY)
3 Range (Manual 3GR)

• Overdrive one-way clutch, holding (drive)
• Intermediate band applied
- Forward ring gear
3 RANGE (MANUAL 3GR)
INTERMEDIATE
BAND APPLIED
COAST CLUTCH FORWARD CLUTCH
APPLIED APPLIED
OVERDRIVE ONE-WAY
CLUTCH HOLDING
(DRIVE ONLY)
arnffn00000395
05-13-13
, .
- Forward ring gear
2 RANGE (MANUAL 2GR)
FORWARD CLUTCH
APPLIED
LOW/REVERSE BAND
APPLIED
OVERDRIVE BAND
APPLIED
LOW/REVERSE ONE-WAY
CLUTCH HOLDING (DRIVE
o ONLY)
arnffn00000396
05-13-14
- Forward ring gear
1 RANGE (MANUAL 1 GR)
FORWARD CLUTCH
APPLIED
COAST CLUTCH LOW/REVERSE BAND
APPLIED OVERDRIVE ONE-WAY APPLIED
ONLY) LOW/REVERSE ONE-WAY
ONLY)
05-13-15
TORQUE CONVERTER OUTLINE [5R55S]
id0513c1321000
• The torque converter of the 5R55S transmission is a four-element component. It contains an impeller, a turbine
and a reactor, plus TCC (torque converter clutch) for increased fuel economy.
• The impeller and cover assembly drives the impeller blades and fluid pump. It contains hydraulic fluid and
provides a mating surface for the TCC damper assembly.
• The turbine is driven by fluid from the impeller and transmits power to the turbine shaft and planetary gearsets.
• The reactor redirects fluid flow returned from the turbine to the impeller so that it rotates in the same direction
as the impeller. This action assists in torque multiplication.
• The reactor has a one-way clutch to hold it stationary during torque multiplication (at lower vehicle speeds) and
allow it to rotate (at higher vehicle speeds).
• TCC has the following features:
A piston with damper assembly that connects to the turbine and transmission input shaft
A friction paper surface on the piston (or on a ring connected to the piston) that makes contact with the
torque converter cover when TCC is applied
Fluid that flows through the torque converter and pushes the TCC piston away from the torque converter
cover during TCC release
Fluid that flows through the torque converter and pushes the TCC piston into contact with the torque
converter cover during TCC apply
• TCC operates in three stages:
Full release
- Controlled modulation
- Full apply
• The TCM controls TCC operation, using the TCC control solenoid.
• TCC control solenoid operation provides the modulation of hydraulic pressure to change the position of the
control valves. The control valves change the pressure and direction of fluid flow in the torque converter.
• TCC may be applied in 2nd gear, 3rd gear, 4th gear and 5th gear.
FULL Tee RELEASE FULL Tee APPLY
TURBINE
REACTOR
FROM
CONVERTER
CONTROLVALVE o
FROM
IMPELLER CONVERTER
CONTROL VALVE
TCC TO
CONVERTER
CONTROL
VALVE AND
LUBE
arnffn00000346
05-13-16
PLANETARY GEARSETS CONSTRUCTION [SRSSS]
id0513c1321100
• The 5R55S transmission has three planetary gearsets to provide operation in reverse and in five forward
speeds.
• The overdrive planetary gearset has the following parts:
- Overdrive sun gear
- Overdrive planetary carrier component
- Overdrive ring gear
• The input shaft rotates the overdrive planetary carrier component as a driving member. The input shaft may
also drive the overdrive ring gear directly with a 1.00 to 1 ratio.
• When the transmission case holds the overdrive sun gear stationary, the overdrive planetary carrier drives the
overdrive ring gear with an overdrive ring gear with an overdrive ratio of either 0.71 to 1.
• The forward and reverse planetary gearsets have the following parts:
Forward/reverse sun gear
Forward planetary carrier component
Forward ring gear
Reverse planetary carrier component
Output ring gear
• The forward/reverse sun gear is a driving member in reverse. The forward ring gear is a driving member in each
forward gear.
• The forward/reverse sun gear and forward ring gear are driving members for a 1.00 to 1 ratio in 4GR and 5GR.
• The forward planetary carrier component and output ring gear are both connected to the output shaft and are
driven members in reverse and in all forward speeds.
• The transmission case holds the reverse planetary carrier component stationary in 1GR and 2GR.
• The reverse planetary carrier component is a member that rotates at a different speed that the driving and
driven members in 3GR.
• The reverse planetary carrier component rotates at the same speed as the forward/reverse sun gear and
forward ring gear as part of the 1.00 to 1 ratio in 4GR and 5GR.
OUTPUT SHAFT
OUTPUT RING GEAR

Ii' ~~
~ ~
o 0 REVERSE PLANETARY
CARRIER ~,
_~
~~~
~
FORWARD
PLANETARY
SUN GEAR AND INPUT
. SHELL
____ -
____________
____- - - - - ~, ~
----
FORWARD CARRIER - ____ -
-----
'~ING GEAR _----
'~'
OVERDRIVE RING
GEAR AND CENTER
-~- SHAFT
~ ____
-~----" " OVERDRIVE
OVERDRIVE
PLANETARY
CARRIER·
~ SUN GEAR
INPUT SHAFT
arnffn00000348
05-13-17
APPLY COMPONENTS CONSTRUCTION [5R55S]
id0513c1321200
Clutch/Band Operation
• The apply components of the 5R55S transmission work together to provide a flow of power.
• The coast clutch is applied to provide coast braking in manual 1GR, manual 3GR and manual 4GR. Coast
braking occurs without the use of the coast clutch in manual 2GR and in 5GR.
D
Position/Range R D (O/D 3 2 1
OFF) Planetary
component
Manual Manual Manual Manual
Gear position Reverse 1GR 2GR 3GR 4GR 5GR
4GR 3GR 2GR 1GR
Overdrive band A A A OS
Intermediate band A A FRS
Low/reverse band A A A RP
Coast clutch A A A OS
Direct clutch A A A A FRS
Forward clutch A A A A A A A A A FR
Overdrive Drive H H OR H H OR H H OR H
one-way OS
clutch Coast OR OR OR OR OR OR OR OR OR OR
Low/ Drive H H OR OR OR OR OR H H
reverse
RP
one-way Coast OR OR OR OR OR OR OR OR OR
clutch
A : Applied
H : Holding
OR: Overrunning
OS: Overdrive sun gear
RP: Reverse planetary carrier component
FRS:Forward/reverse sun gear
FR: Forward ring gear
05-13-18
Overdrive Band
• The overdrive band connects the overdrive sun gear to the transmission case.
• The overdrive band is applied in 2GR and 5GR, as well as in manual 2GR.
• During 2GR and 5GR operation, hydraulic pressure is applied to the overdrive servo.
This pressure causes the piston to move and apply force to the band.
This action causes the overdrive band to hold the overdrive drum.
This causes the overdrive sun gear to be held stationary through the adapter plate and the overdrive drum.
Q SERVO PISTON AND
~~
RETURN SPRING
OVERDRIVE
BAND
~-~
SERVO COVER, SEALS ~
AND RETAINING RING ~
~
~ .' OVERDRIVE SUN
GEAR AND
APPLYSTRUT~~ ADAPTER
COAST CLUTCH
~
DRUM
ANCHOR STRUT,
ADJUSTING SCREW
AND NUT
05-13-19
Overdrive One-Way Clutch
• The overdrive one-way clutch connects the input shaft to the center shaft during drive operation.
• The overdrive one-way clutch transmits torque in Reverse, 1GR, 3GR and 4GR, as well as in manual 3GR.
• The direct one-way clutch is a sprag-type one-way clutch that is pressed into the center shaft.
'
The overdrive one-way clutch is driven by the ring gear of the overdrive planetary carrier. ~ .
The overdrive one-way clutch holds and drives the outer splines of the center shaft in 1GR, 3GR, 4GR and
Reverse gears.
The overdrive one-way clutch overruns during all coast operations and at all times in 2GR and 5GR.
OVERDRIVE ONE-WAY CLUTCH SPRAG

ASSEMBLY AND OUTER RACE (PART OF
OVERDRIVE RING GEAR/CENTER
OVERDRIVE ONE-WAY CLUTCH INNER RACE

(PART OF OVERDRIVE PLANETARY CARRIER)
arnffn00000351
Coast Clutch
• The coast clutch connects the overdrive planetary carrier component to the overdrive sun gear.
• The coast clutch is applied in manual 1GR, manual 3GR, manual 4GR (0 range OlD OFF mode) and Reverse
positions.
• The coast clutch is a multi-disc clutch made up of steel and friction plates.
The coast clutch is applied with hydraulic pressure and disengaged by return springs and the exhaust of
the hydraulic pressure.
The coast clutch is housed in the overdrive drum.
When applied, the coast clutch locks the overdrive sun gear to the overdrive planetary carrier, thus
preventing the one-way clutch from overrunning when the vehicle is coasting.
This allows the use of engine compression to help slow the vehicle and provide engine braking.
OVERDRIVE
PLANETARY
CARRIER
PRESSURE OVERDRIVE SUN
PLATES GEARAND
ADAPTER ~
STEEL
PLATES
~~~
--%~
PISTON AND
SEALS
~ ~
~ ~
~-
COAST
CLUTCH
~ .... f\.\)X:\J
DRU~ (\f0'~~ ~ ~~~~~~~'NG
~~ - \ FRICTION PLATES
~ RETURN SPRINGS,
RETAINER AND
RETAINING RING
arnfin00000352
05-13-20
Intermediate Band
• The intermediate band connects the forward/reverse sun gear to the transmission case.
• The intermediate band is applied in 3GR, as well as in manual 3GR.
• During 3GR operation, hydraulic pressure is applied to the intermediate servo.
This pressure causes the servo to move and apply force to the intermediate band.
This action causes the direct clutch drum to be held.
The intermediate band holds the intermediate brake and direct clutch drum to the case in 3GR.
This causes the input shell and forward sun gear to be held stationary.
SERVO COVER,
SEALS AND
RETAINING RING
.~ INTERMEDIATE
W~ BAND
~
SERVO PISTON
AND SPRING
FORWARD/REVERSE SUN
GEAR AND INPUT SHELL
DIRECT CLUTCH
APPLY STRUT
DRUM
~-
ANCHOR STRUT,
ADJUSTING SCREW
AND NUT
05-13-21
Direct Clutch
• The direct clutch connects the center shaft to the forward/reverse sun gear.
• The direct clutch is applied in Reverse, 4GR and 5GR, as well as in manual4GR (0 range % OFF mode).
• The direct clutch is a multi-disc clutch made up of steel and friction plates.
The direct clutch is applied with hydraulic pressure and disengaged by return springs and the exhaust of
It is housed in the direct clutch drum.
During 4GR, 5GR and Reverse gear application, the direct clutch is applied transferring torque from the
forward clutch cylinder to the direct clutch drum.
This action causes the forward sun gear to drive the pinions of the low/reverse planetary carrier.
FORWARD/REVERSE SUN
GEAR AND INPUT SHELL
FORWARD CLUTCH
CYLINDER
\J
PRESSURE
PLATES
FRICTION ~
PLATES~
ny--
RETURN SPRINGS,
6Jf;Jf(J ~
ETAINERAND
RETAINING RING
•
-'\\J
DIRECT CLUTCH
DRUM ~~.l~
~
~\
~ETAINING RING
(SELECT FIT)
CENTER SHAFT ~ / STEEL
(r
~~ ~ PLATES
rrn PISTON AND

~ SEALS
arnffn00000354
Forward Clutch
• The forward clutch connects the center shaft to the forward ring gear.
• The forward clutch is applied in all forward gears.
• The forward clutch is a multi-disc clutch made up of steel and friction plates.
The forward clutch is applied with hydraulic pressure and disengaged by return springs and the exhaust of
When applied, the forward clutch provides a direct mechanical coupling between the center shaft and the
forward ring gear and hub.
arnffn00000355
05-13-22
Low/Reverse Band
• The low/reverse band connects the reverse planetary carrier to the transmission case.
• The low/reverse band is applied in Reverse, as well as in manual 1GR and manual 2GR.
• During 2GR operation, 1GR operation and Reverse, hydraulic pressure is applied to the low/reverse servo.
This pressure causes the servo to move and apply force to the low/reverse band.
This action causes the low/reverse brake drum to be held.
This action causes the low/reverse planetary assembly to be held stationary.
LOW/REVERSE
/i
/',
BAND
\~
-----v ,/
BAND
~~ J-
, I ACTUATING
LEVER AND
SHAFT
/
LOW/REVERSE
DRUM
SERVO PISTON - - - - 1
ASSEMBLY
arnffn00000356
05-13-23
Low/Reverse One-Way Clutch
• The low/reverse one-way clutch connects the reverse planetary carrier to the transmission case during drive
operation.
• The low/reverse one-way clutch transmits torque in 1GR and 2GR, as well as in manual 1GR and manual 2GR.
• The low/reverse one-way clutch is a sprag-type one-way clutch.
The low/reverse one-way clutch holds the low/reverse drum and low/reverse planetary assembly to the
case in 1GR and 2GR.
In all other gears the low/reverse one-way clutch overruns.
REVERSE PLANETARY
CARRIERAND
RETAINING RING
~ LOW/REVERSE ONE-WAY CLUTCH

ASSEMBLY AND OUTER RACE (PART
OF LOW/REVERSE DRUM)
LOW/REvERSE ONE-WAY CLUTCH INNER
RACE (PART OF TRANSMISSION CASE)
arnffn00000357
05-13-24
PARKING LOCK CONSTRUCTION [5R55S]
id0513c1321300
• The parking gear is connected to the output shaft. The parking gear has lugs on its outer surface to allow the
operation of the parking lock.
• The parking lock prevents the vehicle wheels from rotating by allowing the transmission case to hold the output
shaft stationary through the parking gear. When the parking pawl engages the parking gear, it holds the gear
stationary.
• When the manual control lever is rotated to the P position, the parking lock works as follows:
The inner manual control valve detent lever (connected to the manual control shaft) rotates, pushing a
spring-loaded actuator rod.
The actuator rod pivots the parking pawl into alignment between the lugs of the parking gear.
The parking pawl (connected to the transmission case) holds the parking gear.
PARKING PAWL, SHAFT

ACTUATOR ROD
AND SPRING
~
I
.' MANUAL SHAFT
'~~" 'h.Q.
""'-
J"
DETENT SPRING
INNER MANUAL
VALVE DETENT
LEVER
!~
DIGITAL TR
SENSOR MANUAL SHAFT
LEVER
arnffn00000358
05-13-25
LUBRICATION [SRSSS]
id0513c1321500
• The 5R55S transmission provides lubrication for rotating mechanical components through three hydraulic
circuits to the front, center and rear areas. Fluid in the torque converter hydraulic circuit provides fluid to
lubricate the impeller hub bushing.
• Fluid in this circuit also flows from the transmission case, through a tube, to a cooler located at the front of the
vehicle. Fluid from the cooler returns through another tube into the transmission and then through the three
lube circuits.
• When the temperature of fluid that exits the torque converter contains less heat, the action of a thermostatically
controlled valve in the main control causes the cooler to be bypassed. Fluid flows directly from the torque
converter into the lube circuits.
• As transmission fluid temperature increases, the thermostatically controlled valve allows directs the flow of fluid
exiting the torque converter to pass through the cooler before it enters the lube circuits.
FRONT LUBE
arnffn00000359
05-13-26
FLUID PUMP CONSTRUCTION [5R55S]
id0513c1323500
• The 5R55S transmission has a gear type pump that supplies fluid under pressure to the hydraulic system.
• The fluid pump provides the fluid pressure necessary to charge the torque converter, main control assembly,
transmission cooling system, lubrication system and apply devices.
• The torque converter impeller hub rotates the drive gear of the pump. The drive gear has an O-ring on its
impeller hub contact surface.
• The fluid pump has the following parts:
Pump cover
Adapter plate
Pump assembly, with drive and driven gears and an integral stator support
STATOR SUPPORT
SEAL FLUID PUMP BODY
WITH GEARS
FLUID PUMP COVER,
ADAPTER PLATE AND
GASKET
IMPELLER HUB
SEAL
TORQUE CONVERTER
FLUID PUMP
CONTROL VALVE
FLUID PUMP INNER AND SEAL
GEAR O-RING SEAL
FLUID PUMP BODY

OUTER SEAL
05-13-27
FLUID FILTER CONSTRUCTION [5R55S]
id0513c1321600
• Fluid in a sump area formed by the fluid pan flows from a filter, through passages in the valve body and
transmission case, to the suction port of the fluid pump.
• The transmission fluid filter and its accompanying seals are part of the fluid path from the sump (pan) to the
fluid pump.
- The transmission fluid filter has a bypass section which allows fluid vented at the main regulator valve to be
recirculated to the fluid pump, without passing through the transmission fluid filter.
• A magnet attached to the inside of the fluid pan collects unwanted magnetic material.
TRANSMISSION
CASE
FROM MAIN
REGULATOR
VALVE
FLUID PUMP
SUCTION
FLUID
FILTER
FLUID PAN AND

GASKET
I A FLUID LEVEL
~ INDICATOR PLUG
DRAIN PLUG ~ arnfln00000361
05-13-28
CONTROL VALVE BODY OUTLINE [SR5SS]
id0513c1636600
• The control valve body component and related components are part of the pressure side of the hydraulic
system.
• The control valve body component consists of the solenoids, the valve body assembly and the separator plate.
• These components combine to convert electrical signals into hydraulic actions.
All valves in the control valve body component are anodized aluminum and cannot be sanded, filed or
dressed in any other way. If there is any damage to the valves that prevents or restricts their movement,
install a new control valve body component.
TRANSMISSION CASE
SEPARATOR PLATE WITH

BONDED GASKET
CONTROL
VALVE BODY
COMPONENT
~
e \,
~-
. ~-\
,
SOLENOID BODY
COMPONENT AND
O-RING SEALS
\b , .0
LOW/REVERSE
SERVO ASSEMBLY
LOW/REVERSE SERVO
CONTROL VALVE ~~
~
\) ~ \
\ arnffn00000362
05-13-29
Control Valve Body Component Exploded View
b5r5za00000083
1 Retainer clip 30 Reverse modulator valve

2 Retainer plug 31 Reverse modulator valve spring
3 Thermo valve component 32 Retainer clip
4 Fluid cooler bypass valve 33 Retainer plug
5 Fluid cooler bypass spring 34 Reverse engagement valve
6 Retainer clip 35 Reverse engagement valve spring
7 Retainer plug 36 Retainer clip
8 Converter clutch control valve spring 37 Retainer plug
9 Converter clutch control valve 38 VFS1 modulator valve
10 Plate 39 VFS1 modulator valve spring
11 Coast clutch control spring 40 Retainer clip
12 Coast clutch control valve 41 Sleeve
13 Retainer clip 42 Booster valve
14 Retainer plug 43 Booster valve
15 Converter clutch back pressure valve 44 Inner spring
16 Converter clutch back pressure spring 45 Outer spring
17 Retainer clip 46 Retainer spring
18 Retainer plug 47 Main regulator valve
19 VFS2 modulator valve 48 Retainer clip
20 VFS2 modulator valve spring 49 Retainer plug
21 Retainer clip 50 Converter limit spring
22 Retainer plug 51 Converter limit valve
23 Intermediate servo release valve 52 Plate
24 Intermediate servo release valve spring 53 Solenoid regulator valve spring
25 Plate 54 Solenoid regulator valve
26 High clutch control spring 55 Manual valve
27 High clutch control Valve 56 Retainer clip
28 Retainer plug 57 Retainer plug
29 Retainer clip 58 Rear servo control valve spring
05-13-30
59 Rear servo control valve 70 Overdrive servo control valve

60 Retainer clip 71 Clip retainer
61 Retainer plug 72 Converter clutch modulator control sleeve
62 RS ISA select valve spring 73 Converter clutch modulator control valve
63 RS ISA select valve 74 Converter clutch modulator valve
64 Retainer clip 75 Converter clutch modulator control spring
65 Retainer plug 76 Separator plate
66 Forward engagement control valve spring 77 Lubrication check ball
67 Forward engagement control valve 78 Shuttle valve ball
68 Plate 79 Lower control valve body
69 Overdrive servo control spring 80 Bolt
05-13-31
PRESSURE CONTROL HYDRAULIC CIRCUITS CONSTRUCTION [5R55S]
id0513c1321800
Line Pressure Hydraulic Circuit

• Fluid under pressure from the pump flows to several hydraulic controls in the valve body, including the main
regulator valve. The main regulator valve varies line pressure as part of controlling shift feel and efficient apply
component operation.
• The TCM controls the. position of the main regulator valve with the pressure control solenoid A and B.
• When pressure control solenoid A and B pressures are lower, the main regulator valve position provides lower
line pressure. As the fluid pressures from pressure control solenoid A and B increase, the main regulator valve
provides higher line pressure.
• When the transmission shifter is in the R position, fluid under pressure from the manual valve to the apply
components also affects the position of the main regulator valve. This results in a pressure boost.
LINE PRESSURE CIRCUITS

(SHOWN IN P POSITION)
INTERMEDIATE
REVERSE PRESSURE
CONTROL VALVE FROM PCB
MODULATOR VALVE
FROM
REVERSE - - - - , ------ FROM PC A
CIRCUIT
MAIN
I!:rI=FTr~~~~ REGULATOR
VALVE
r-------------~--~------~
CONVERTER
CLUTCH LIMIT
VALVE
SOLENOID FEED
OVERDRIVE SERVO
CONTROL VALVE
TORQUE
CONVERTER
............... ~
LIMIT VALVE
LUBE
CIRCUITS
r --' PRND321
I
- - - - _I
Il ~~Ir
~t'-F=ILT,-=E.R
L-_ _
I SUMP
I
arnffn00000363
05-13-32
Pressure Control Solenoid A Hydraulic Circuit
• In the 5R55S transmission, pressure control solenoid A affects the operation of the main regulator valve and
the VFS1 modulator control valve .
• VFS1 pressure indirectly affects the feel of the forward clutch engagement. VFS1 pressure is directly applied to
the intermediate servo. It is also directly applied to the low/reverse servo in manual 1GR and manual 2GR.
PRESSURE CONTROL SOLENOID A LOW/REVERSE

CIRCUITS (SHOWN IN 3GR) SERVO
INTERMEDIATE
BAND SERVO
Dp
DIRECT FORWARD
CLUTCH CLUTCH
1
--1
1
1
1 VFS1 MODULATOR
.I :
1 CONTROL VALVE
I
I
1
,- - - - --- -- --- - - --- - - - - - ~- - - - - - -- ---,
1
:
1
:, I :,
,1-------- 4-- ____ I :,
,
11 MAIN
REGULATOR
VALVE
11
VFS2 11
~
__I
OVERDRIVE SERVO
CONTROL VALVE
FORWARD INTERMEDIATE REVERSE
ENGAGEMENT SERVO SELECT SERVO
CONTROL VALVE VALVE CONTROL
VALVE
~--------------------------------
LINE - - - - -....- - - - - - - - - - - - - ' MANUAL

VALVE
PRND321
arnffn00000364
05-13-33
Pressure Control B Solenoid B Hydraulic Circuit
• In the 5R55S transmission, pressure control solenoid 8 affects the operation of the main regulator valve, the
VFS2 modulator control valve, the forward engagement control valve and the reverse engagement control
valve.
• VFS2 pressure indirectly affects the feel of the forward clutch engagement, as well as the direct clutch
engagement in reverse. VFS2 pressure is directly applied to the overdrive servo or the coast clutch.

CIRCUITS (SHOWN IN 2GR)
COAST OVERDRIVE BAND

CLUTCH SERVO
DIRECT FORWARD
CLUTCH CLUTCH
REVERSE
VFS2 MODULATOR
COAST CLUTCH ENGAGEMENT
CONTROL VALVE
CONTROL VALVE CONTROL
VALVE
I--
I
I
I
I
I
I
I
I
I MAIN
I
I
I
1!:rI=:::I/::::ilIr-I:ff~~~ REGULATOR
I
VALVE
I
I
I
I
..
I
I
______ ... I
L...-_-('[I,I
----------
FORWARD
OVERDRIVE SERVO ENGAGEMENT
CONTROL VALVE CONTROL VALVE MANUAL
VALVE
PRND321
LINE - - - - - - - - -...............- - - - - - -...
arnifn00000365
05-13-34
Pressure Control Solenoid C Hydraulic Circuit
• In the 5R55S transmission, pressure control solenoid C solenoid affects the operation of the reverse pressure
modulator valve and the reverse engagement control valve.
• Pressure control solenoid C pressure indirectly affects the feel of direct clutch engagement in reverse. Pressure
control solenoid C pressure is directly applied to the direct clutch in 4GR and 5GR.

CIRCUITS (SHOWN IN R POSITION)
DIRECT FORWARD
CLUTCH CLUTCH
•
##~
••••• J
: DIRECT
REVERSE REVERSE
• CLUTCH PRESSURE ENGAGEMENT
:CONTROL
MODULATOR CONTROL
: VALVE VALVE VALVE
••
•
... I
...~ i
r-----+----+-·
I
I
I
I PRND321
LlNE--........................~~................~~....................................................~
arnffn00000366
05-13-35
SHIFT SOLENOID HYDRAULIC CIRCUITS CONSTRUCTION [5R55S]
id0513c1321900
Solenoid Feed Hydraulic Circuit
• In the 5R55S transmission, fluid under line pressure moves to the solenoid feed limit valve. The solenoid feed
limit valve provides fluid under a steady regulated pressure to the shift solenoids and TCC control solenoid.
• The TCM operates the shift solenoids with on/off control. When the TCM turns off each solenoid, fluid flow is
blocked. When the TCM turns on each solenoid, full fluid flow occurs.
• The TCM operates the TCC control solenoid with varying Pulse-Width Modulation (PWM) control. This results
in variable fluid flow and pressure from the TCC control solenoid to the hydraulic valve it controls.
SOLENOID FEED CIRCUITS

(SHOWN IN 1 GR)
CONVERTER
CLUTCH LIMIT
VALVE
SOLENOID
FEED LIMIT
VALVE
LINE - - - - - - - - - - - - - -.....
OFF ON OFF OFF ON

arnffn00000367
05-13-36
Shift Solenoid A Hydraulic Circuit
• In the 5R55S transmission, shift solenoid A affects the operation of the direct clutch. When shift solenoid A is
on in forward speeds, the direct clutch is released. When shift solenoid A is turned off, the direct clutch is
applied. shift solenoid A is also related to the operation of the intermediate band.
• When the transmission shifter is moved to the R position under conditions that may cause transmission
damage, the TCM turns off shift solenoid A to inhibit reverse operation. This affects various hydraulic control
valves in order to keep the direct clutch released.
SHIFT SOLENOID A CIRCUITS

(SHOWN IN 4GR)
INTERMEDIATE
BAND SERVO
DIRECT FORWARD
CLUTCH CLUTCH
DIRECT CLUTCH
CONTROL VALVE
FROM RE VERSE
.:.u:-==== PRESSURE MODULATOR
VALVE
SS1
- - FROM VFS1 MODULATOR

CONTROL VALVE
INTERMEDIATE
SERVO SELECT
VALVE
, - - - - FROM SOLENOID
FEED LIMIT VALVE
OFF
arnffn00000368
05-13-37
Shift Solenoid 8 Hydraulic Circuit
• In the 5R55S transmission, shift solenoid B affects the operation of the intermediate band. When shift solenoid
B is on, the intermediate band is applied. When shift solenoid B is turned off, the intermediate band is released.
shift solenoid B is also related to the operation of the low/reverse band in manual 1st gear and manual 2nd
gear.
• The TeM does not use shift solenoid B to inhibit reverse operation in 5R55S transmission.
SHIFT SOLENOID B CIRCUITS

(SHOWN IN 3GR)
LOW/REVERSE
SERVO
INTERMEDIATE
BAND SERVO
SMALL AREA
INTERMEDIATE LARGE AREA

CONTROL VALVE
FROM VFS1 MODULATOR

CONTROL VALVE
SS4
SS2
INTERMEDIATE REVERSE
SERVO SELECT SERVO
VALVE CONTROL
VALVE
,....-_ _ _ _ _ FROM SOLENOID FEED

LIMIT VALVE
ON
arnffn00000369
05-13-38
Shift Solenoid C Hydraulic Circuit
• In the 5R55S transmission, shift solenoid C affects the operation of the overdrive band. When shift solenoid C
is on, the overdrive band is applied. When shift solenoid C is turned off, the overdrive band is released.
SHIFT SOLENOID C CIRCUITS

(SHOWN IN 2GR)
OVERDRIVE BAND
SERVO
Re :OSR
1
1
1
1
1-------------------------------1
1
1
1
1
1
.----1-----<;"--;1 SS3
1
1
1
1____ -
1
L___ FROM VFS2 MODULATOR
CONTROL VALVE
OVERDRIVE SERVO
CONTROL VALVE
FROM SOLENOID
, . . . . - - - - - - - - - FEED LIMIT VALVE
ON
05-13-39
Shift Solenoid 0 Hydraulic Circuit
• In the 5R55S transmission, shift solenoid D affects the operation of the coast clutch. When shift solenoid D is
on, the coast clutch is released. When shift solenoid D is turned off, the coast clutch is applied.
SHIFT SOLENOID D CIRCUITS

(SHOWN IN MANUAL 3GR)
COAST CLUTCH
1
1
,~
1
1
1--------------- 1
1
1
1
: COAST CLUTCH
: CONTROL
1 VALVE
1
1
1
1
L __ _
SS3rr=l'--
------1
1
1___ • FROM VFS2 MODULATOR
CONTROL VALVE
OVERDRIVE SERVO
CONTROL VALVE
FROM SOLENOID
r------------ FEED LIMIT VALVE
OFF
arnffn00000371
05-13-40
Torque Converter Clutch (TCC) Control Solenoid Hydraulic Circuit
• In the 5R558 transmission, the Tee control solenoid affects the operation of the torque converter clutch in
forward speeds.
• Tee pressure affects the positions of the converter pressure modulator valve and the converter control valve.
TCC CONTROL SOLENOID CIRCUITS
(SHOWN WITH TCC APPLY)
....
\
j
~
CON...r:VE:::1R~TdE~R~W~Ir-TH911====~ THERMOSTAT BYPASS VALVE
TORQUE CONVERTER I (HOT POSITION)
CLUTCH I CONVERTER CONTROL
I VALVE
I
I
I
I
I -EXHAUST
FROM CONVERTER
CLUTCH LIMIT VALVE
CONVERTER
PRESSURE
MODULATOR VALVE
MANUAL
VALVE
PRND321
FROM SOLENOID
, - = = = = = = = - - - FEED LIMIT VALVE
arnffn00000372
05-13-41
TORQUE CONVERTER/LUBE HYDRAULIC CIRCUITS CONSTRUCTION [5R55S]
id0513c1322000
• In the 5R55S transmission, fluid for torque converter operation flows as follows during TCC release:
- From the LINE circuit, through the converter clutch limit valve, through the converter control valve, to the
torque converter
- From the torque converter, through the converter control valve, into the lube circuits
• The thermostat bypass valve allows fluid from the torque converter to bypass the fluid cooler and enter into the
lube circuits when fluid temperature is cold.
TORQUE CONVERTER/LUBE CIRCUITS
"~- {---------,
" -
(SHOWN WITH TCC RELEASE)
JI
CONVERTER WITH
TORQUE CONVERTER
CLUTCH NOT APPLIED
..--------.,"
"
::
"
::THERMOSTAT BYPASS VALVE
:: (COLD POSITION)
:: CONVERTER CONTROL
" VALVE
" -
rr===i====*=,======11 b ====.
" r-
"" L_="
" rlr
• " ,"
• • • • • • •II• • t4 •••• i==T
I>- - ~.- - - EXHAUST
II
, ______ LL_ II ___
...... :;::; >- ............ ..
:: ------rr--.---
------------- :;::;
FROM MAIN
REGULATOR VALVE =
""
"
"
-::=:
"
"
REAR LUBRICATION "
"
rF==;;;~::::~~~~=i REAR/LUBE "
"
t ........ LINE
*B SHUTTLE BALL "
:S~L!::::::==.
"
"
CENTER LUBRICATION "
" •
FRONT LUBRICATION
"
"
.- tt CONVERTER CLUTCH
"
"
~l ~ [RJI LIMIT VALVE
" SOLENOID FEED
ffi II: "
CONVERTER BUSHING
"B-
LIMIT VALVE
(5 ~ ~:ri-----?ft:~~~~~~TR~=.:!,
86 8~ (MAJORITY OF FLOW
LINE
ICOOLERI BYPASSES COOLER)
TO SUMP
arnffn00000373
05-13-42
• When TCC is applied, fluid for torque converter operation flows as follows:
From the LINE circuit, through the converter clutch limit valve, through the converter control valve, into the
lube circuits
From the LINE circuit, through the converter pressure modulator valve, through the converter control valve,
to the torque converter
TORQUE CONVERTER/LUBE CIRCUITS

(SHOWN WITH TCC APPLY)
CONVERTER WITH-I
TORQUE CONVERTER I
CLUTCH I
THERMOSTAT BYPASS VALVE
I (HOT POSITION)
I CONVERTER CONTROL
I VALVE
I
I 1===
,I"
I ,I"
IL _ _ " - - - EXHAUST
--1'-
",I
...... -.
ji====== =~==- ••
" ••
"
FROM MAIN " •
REGULATOR VALVE "
"
" •
" . ············t
REAR LUBRICATION "
" •
W=====~~~~~~~==*REA~LUBE "
"
t··· . LINE
* B a SHUTTLE BALL "
"
"" CONVERTER PRESSURE
CENTER LUBRICATION " MODULATOR VALVE
" CONVERTER CLUTCH
FRONT LUBRICATION "
"
FROMTCC LIMIT VALVE
"" SOLENOID SOLENOID FEED
ffi ffi CONVERTER BUSHING LIMIT VALVE
-' -"Iq--------~ LUBRICATION
01-
O::J A_Jol ------------.
0""L-.:....J~------------
I
() 0 8, (MAJORITY OF FLOW
LINE
COOLER BYPASSES COOLER)
TO SUMP
arnffn00000374
05-13-43
APPLY COMPONENT HYDRAULIC CIRCUITS CONSTRUCTION [5R55S]
id0513c13221 00
P and N Positions (Park and Neutral)

• With the transmission in the P or N position, fluid under pressure is present at the following components:
Overdrive servo-release
- Intermediate servo-release
LOW/REVERSE
P POSITION SERVO
COAST
OVERDRIVE BAND INTERMEDIATE
CLUTCH
SERVO BAND SERVO
DIRECT FORWARD
CLUTCH CLUTCH
COAST CLUTCH
CONTROL VALVE
DIRECT CLUTCH
CONTROL VALVE
REVERSE
SERVO AREA
CONTROL
VALVE
SERVO SELECT ENGAGEMENT
VALVE CONTROL
SS1 VALVE
VFS1 REVERSE
~n--'"'"T"'r'tH MODULATOR PRESSURE
CONTROL MODULATOR
VALVE VALVE
INTERMEDIATE
CONTROL VALVE
VFS2
CT"T.I--I------, MODULATOR
CONTROL
VALVE
OVERDRIVE
SERVO
CONTROL
VALVE REVERSE
SERVO
CONTROL
VALVE
MANUAL
LINE VALVE
FORWARD
ENGAGEMENT
PRND321 CONTROL VALVE
arnffn00000375
05-13-44
R Position (Reverse)
• With the transmission in the R position, fluid under pressure is present at the following components:
Intermediate servo-release
Direct clutch
Low/reverse servo-apply
LOW/REVERSE
R POSITION SERVO
COAST
CLUTCH
SERVO BAND SERVO
DIRECT FORWARD
CLUTCH CLUTCH
COAST CLUTCH
CONTROL VALVE
DIRECT CLUTCH
CONTROL VALVE
REVERSE
SERVO AREA
CONTROL
VALVE
VALVE CONTROL
VALVE
VFS1 REVERSE
MODULATOR PRESSURE
CONTROL MODULATOR
VALVE VALVE
INTERMEDIATE
CONTROL VALVE
VFS2
~=:t==~ MODULATOR
CONTROL
VALVE
OVERDRIVE
SERVO
CONTROL
VALVE REVERSE
SERVO
CONTROL
VALVE
MANUAL
VALVE
LINE
FORWARD
ENGAGEMENT
arnffn00000376
05-13-45
D Range, 1GR
• With the transmission in the D range, fluid under pressure is present at the following components in 1GR:
Forward clutch
LOW/REVERSE
D RANGE 1GR SERVO
COAST
CLUTCH
SERVO BAND SERVO
DIRECT FORWARD
CLUTCH CLUTCH
COAST CLUTCH
CONTROL VALVE
DIRECT CLUTCH
CONTROL VALVE
REVERSE
SERVO AREA
CONTROL
VALVE
VALVE CONTROL
VALVE
VFS1 REVERSE
--=.Jr..............,.., MODULATOR PRESSURE
CONTROL MODULATOR
VALVE VALVE
INTERMEDIATE
CONTROL VALVE
~=::J:::==: MODULATOR
.:r VFS2
CONTROL
VALVE
OVERDRIVE
SERVO
CONTROL
VALVE REVERSE
SERVO
CONTROL
VALVE
MANUAL
LINE VALVE
FORWARD
ENGAGEMENT
arnffn00000377
05-13-46
D Range, 2GR
Overdrive servo-apply
Forward clutch
LOW/REVERSE
D RANGE 2GR SERVO
COAST
CLUTCH
SERVO BAND SERVO
DIRECT FORWARD
CLUTCH CLUTCH
COAST CLUTCH
CONTROL VALVE
DIRECT CLUTCH
CONTROL VALVE
REVERSE
SERVO AREA
CONTROL
VALVE
VALVE CONTROL
VALVE
VFS1 REVERSE
MODULATOR PRESSURE
CONTROL MODULATOR
VALVE VALVE
INTERMEDIATE
CONTROL VALVE
[I5=+==: VFS2
MODULATOR
CONTROL
VALVE
OVERDRIVE
SERVO
CONTROL
VALVE REVERSE
SERVO
CONTROL
VALVE
MANUAL
LINE VALVE
FORWARD
ENGAGEMENT
arnffn00000378
05-13-47
Drange,3GR
Intermediate servo-apply
Forward clutch .......
LOW/REVERSE
D RANGE 3GR SERVO
COAST
~~
CLUTCH
SERVO BAND SERVO
DIRECT FORWARD
CLUTCH CLUTCH ~~p
COAST CLUTCH
~~I ~ ~~
CONTROL VALVE 'ftJ
-:;=;r- Jj SMALL AREA
DIRECT CLUTCH LARGE AREA

,;::::
COf:i!"RO,!:.YALVE
;=t-· - ==
~ REVERSE
SERVO AREA
~
~
/-- CONTROL
4r1
LJ INTERMEDiATE
VALVE
REVERSE
VALVE CONTROL
~
VFS1 REVERSE ~
MODULATOR PRESSURE
CONTROL ~I
[]
MODULATOR
VALVE VALVE
-:;::;-
- INTERMEDIATE :::;
VFS2
CONTROL VALVE
-
~
-
t;n';I--t--~ MODULATOR /--
lJf
'-- -:r: '1' CONTROL --f=-
,!:!
OVERDRIVE
VALVE
jj
SERVO ~t
CONTROL J g
VALVE REVERsE
SERVO
CONTROL
=;
VALVE
I
LINE
J
I
MANUAL
VALVE
~
~
I--i
FORWARD
ENGAGEMENT
arnffn00000379
05-13-48
D range, 4GR
Forward clutch
Direct clutch
LOW/REVERSE
D RANGE4GR SERVO
COAST
CLUTCH
SERVO BAND SERVO
DIRECT FORWARD
CLUTCH CLUTCH
COAST CLUTCH
CONTROL VALVE
DIRECT CLUTCH
CONTROL VALVE
REVERSE
SERVO AREA
CONTROL
VALVE
VALVE CONTROL
VALVE
VFS1 REVERSE
~~~~ MODULATOR PRESSURE
CONTROL MODULATOR
VALVE VALVE
INTERMEDIATE
CONTROL VALVE
VFS2
q-I,I--I---. MODULATOR
CONTROL
VALVE
OVERDRIVE
SERVO
CONTROL
VALVE REVERSE
SERVO
CONTROL
VALVE
MANUAL
VALVE
LINE
FORWARD
ENGAGEMENT
arnffn00000380
05-13-49
Drange,5GR
Forward clutch
Direct clutch
LOW/REVERSE
D RANGE 5GR SERVO
~~~
COAST
CLUTCH
SERVO BAND SERVO
~ DIRECT FORWARD
I , CLUTCH CLUTCH
COAST CLUTCH ~a ~In ~ ~~

I
CONTROL VALVE RJ
-ij=jr- SMALL AREAY·
DIRECT CLUTCH LARGEAREA~
L~ CONTROL VALVE
~r'-' - - r-
F'i
REVERSE
I=-
~
SERVO AREA
~
I---" CONTROL
1]
L- INTERrviEisiATE
I
VALVE
REVERSE
VALVE R CONTROL
!...d
~V.E
~
VFS1 ~
la---" MODULATOR
REVERSE
PRESSURE
tr
I~~ CONTROL
VALVE
MODULATOR
VALVE IFi
--
-;C;-
INTERMEDIATE
CONTROL VALVE
- r-
ra
_~
~t':...1n=:::t=~ VFS2
MODULATOR
CONTROL
~
==9 -~ -
loJ
_
[i L---
VALVE
II
L -_ _~_ _ _ _ _ _ _ _ _ _~_ _r-~kd
OVERDRIVE
--B
r=i
SERVO
CONTROL ~
~----~-+----------~--~ REVERsE
A1
VALVE
SERVO
CONTROL
VALVE n
I
II!=II
LINE
MANUAL
VALVE
II
FORWARD
ENGAGEMENT
arnffn00000381
05-13-50
D range OlD OFF Mode, 4GR (Manual 4GR)
• With the transmission in the 0 range (OlD OFF mode), fluid under pressure is present at the following
components in manual 4GR:
Forward clutch
Direct clutch
Coast clutch
LOW/REVERSE
D RANGE MANUAL 4GR (OlD OFF) SERVO
COAST
CLUTCH
SERVO BAND SERVO
DIRECT FORWARD
CLUTCH CLUTCH
COAST CLUTCH
CONTROL VALVE
DIRECT CLUTCH
CONTROL VALVE
REVERSE
SERVO AREA
CONTROL
VALVE
VALVE CONTROL
VALVE
VFS1 REVERSE
MODULATOR PRESSURE
CONTROL MODULATOR
VALVE VALVE
INTERMEDIATE
CONTROL VALVE
g:g=:::t:==: VFS2
MODULATOR
CONTROL
VALVE
OVERDRIVE
SERVO
CONTROL
VALVE REVERSE
SERVO
CONTROL
VALVE
MANUAL
LINE VALVE
FORWARD
ENGAGEMENT
arnffn00000382
05-13-51
• With the transmission in the 3 range, fluid under pressure is present at the following components in manual
3GR:
Intermediate servo-apply
Forward clutch
Coast clutch
LOW/REVERSE
3 RANGE MANUAL 3GR SERVO
COAST
CLUTCH
SERVO BAND SERVO
DIRECT FORWARD
CLUTCH CLUTCH
COAST CLUTCH
CONTROL VALVE
DIRECT CLUTCH
CONTROL VALVE
REVERSE
SERVO AREA
CONTROL
VALVE
VALVE CONTROL
VALVE
VFS1 REVERSE
1....kr-'ld::::tlrt1ll MODULATOR PRESSURE
CONTROL MODULATOR
VALVE VALVE
INTERMEDIATE
CONTROL VALVE
VFS2
IJI.!--+----, MODULATOR
CONTROL
VALVE
OVERDRIVE
SERVO
CONTROL
VALVE
MANUAL
LINE VALVE
FORWARD
ENGAGEMENT
arnffn00000383
05-13-52
2GR:
Forward clutch
LOW/REVERSE
COAST
CLUTCH
SERVO BAND SERVO
DIRECT FORWARD
CLUTCH CLUTCH
COAST CLUTCH
CONTROL VALVE
DIRECT CLUTCH
CONTROL VALVE
212
REVERSE
SERVO AREA
CONTROL
VALVE
VALVE CONTROL
VALVE
VFS1 REVERSE
----=-1-.-.......,.., MODULATOR PRESSURE
CONTROL MODULATOR
VALVE VALVE
INTERMEDIATE
CONTROL VALVE
aE:=:t===: VFS2
MODULATOR
CONTROL
VALVE
OV D E
SERVO
CONTROL
VALVE REVERSE
SERVO
CONTROL
VALVE
MANUAL
LINE VALVE
FORWARD
ENGAGEMENT
arnffn00000384
05-13-53
1 Range (Manual 1 GR)
1GR:
Forward clutch
Coast clutch
LOW/REVERSE
COAST
~~,
CLUTCH
SERVO BAND SERVO
~ DIRECT FORWARD
I ~ CLUTCH CLUTCH
~ F~
COAST CLUTCH ~~ ~~ll1 11 ~
-U-
CONTROL VALVE ~
~SMALLAREA
DIRECT CLUTCH LARGE AREAI----'
CONTROL VALVE
'----<M - - r--
;----'r'--'
REaRSE
en SERVO AREA
~
:-- IF9 CONTROL
11
"-'
..-1:::,-- VALVE
SERVO SELECT Ip ENGAGEMENT
VALVE CONTROL
1=
'--
~VE
~
VFS1 REVERSE ~
I'\. MODULATOR PRESSURE
IS-d-:::j CONTROL MODULATOR
VALVE VALVE
-c-
- INTERMEDIATE
CONTROL VALVE
~
- r-
VFS2 ~
~=:I==~ MODULATOR F=9
L...........<~ CONTROL III
,== VALVE
OVERDRIVE
SERVO
CONTROL
VALVE
~
REVERsE
SERVO
CONTROL
VALVE IF"'
I
LINE
[~r====~~rll MANUAL
VALVE £~
~
FORWARD
111111 I I ENGAGEMENT
arnffn00000385
05-13-54
ELECTRONIC CONTROL SYSTEM OUTLINE [SRSSS]
id0513c1221600
• The TCM and its input/output network control the following transmission operations:
- Shift timing
- Line pressure (shift feel)
- Torque converter clutch
• The transmission control strategy combined with the engine control provides optimum powertrain operation
under all conditions.
• When determining the best operating strategy for transmission operation, the TCM uses input information from
the PCM via the CAN bus. In addition, the TCM receives input signals from certain transmission-related
sensors and switches.
• The TCM also uses these signals when determining transmission operating strategy.
• Using all of these input signals, the TCM can determine when the time and conditions are right for a shift or
when to apply or release the torque converter clutch.
• It will also determine the pressure needed to optimize shift feel.
• To accomplish this the PCM uses 3 pressure controls, 1 torque converter clutch and 4 shift solenoids to control
transmission operation.
ELECTRONIC CONTROL SYSTEM BLOCK DIAGRAM [SRSSS]

id0513c1218800
INPUT OUTPUT
TURBINE SHAFT SPEED (TSS) SENSOR PRESSURE CONTROL SOLENOID A
INTERMEDIATE SHAFT SPEED (ISS)

SENSOR
OUTPUT SHAFT SPEED (OSS) SENSOR PRESSURE CONTROL SOLENOID C
TRANSMISSION FLUID TEMPERATURE

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

SHIFT SOLENOID B
SENSOR
TCM
OlD OFF SWITCH SHIFT SOLENOID C
PCM
SHIFT SOLENOID D
• ACCELERATOR PEDAL POSITION
(APP) SENSOR
ENGINE COOLANT TEMPERATURE TORQUE CONVERTER CLUTCH (TCC)

(ECT) SENSOR CONTROL SOLENOID
MASS AIR FLOW (MAF) SENSOR
INTAKE AIR TEMPERATURE (IAT)

SENSOR
OlD OFF INDICATOR LIGHT
CRANKSHAFT POSITION (CKP)
SENSOR
BRAKE SWITCH MALFUNCTION INDICATOR LAMP (MIL)
arnffn00000386
05-13-55
ELECTRONIC CONTROL SYSTEM STRUCTURE [5R55S]
id0513c1221900
TCM
• The operation of the transmission is controlled by the TCM.
• Many input sensors provide information to the TCM. The TCM then controls the actuators which determine
transmission operation.
AirConditioning (AlC) Clutch

• An electromagnetic clutch is energized when the clutch cycling pressure switch closes.
• The switch is located on the suction accumulator/drier.
• The closing of the switch completes the circuit to the clutch and draws it into engagement with the compressor
driveshaft.
• When the AlC is engaged, operating pressures are adjusted to compensate for additional load on the engine.
Brake Switch
• The brake switch tells the PCM when the brakes are applied.
• The PCM sends this message to TCM via CAN bus.
• The torque converter clutch disengages when the brakes are applied.
• The brake switch closes when the brakes are applied and opens when they are released.
Engine Coolant Temperature (ECT) Sensor

• The ECT sensor detects temperature of engine coolant and supplies the information to the PCM.
• The PCM sends this message to TCM via CAN bus. .
• The ECT sensor is used to control torque converter clutch (TCC) operation.
Crankshaft Position (CKP) Sensor

• The CKP sensor detects pulse wheel rotational signals as crank angle signals.
• The PCM uses engine speed signal in the transmission strategy, wide-open throttle (WOT) shift control, torque
converter clutch control and operating pressures.
Mass Air Flow (MAF) Sensor

• The MAF sensor measures the mass of air flowing into the engine.
• The MAF sensor output signal is used by the PCM to calculate injector pulse width.
• For transmission strategies, the MAF sensor is used to regulate electronic pressure control, shift and torque
converter clutch scheduling.
010 OFF Switch

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

• The OlD OFF indicator light is located in the instrument panel and is labeled % OFF. It is illuminated in
conjunction with the % OFF switch.
Accelerator Pedal Position (APP) Sensor

• The APP sensor is mounted on the accelerator pedal. The APP sensor detects the position of the accelerator
pedal and inputs this information as a voltage to the PCM.
• The TCM uses the APP sensor information to aid in determining shift scheduling, presser control and torque
converter control.
Digital Transmission Range (TR) Sensor

• The digital TR sensor is located on the outside of the transmission at the mariuallever.
• The digital TR sensor completes the start circuit in PARK, NEUTRAL and the back-up lamp circuit in
REVERSE.
• The digital TR sensor also opens and closes a set of 4 switches that are monitored by the TCM to determine
the position of the manual lever (P, R, N, 0, 3, 2, 1).
05-13-56
Turbine Shaft Speed (TSS) Sensor
• The TSS sensor is a magnetic pickup that sends the TCM torque converter turbine speed information.
• The TSS sensor is mounted externally on the case.
• The TCM uses TSS information to help determine appropriate operating pressures and TCC operation.
Output Shaft Speed (OSS) Sensor

• The OSS sensor is a magnetic pickup, located at the park gear trigger wheel assembly, that sends a signal to
the TCM to indicate transmission output shaft speed.
• The OSS sensor is mounted externally on the case.
• The OSS is used for torque converter clutch control, shift scheduling and to determine pressure control.
Intermediate Shaft Speed (ISS) Sensor

• The ISS sensor is a magnetic pickup that sends planetary sun gear speed information to the TCM.
• It is mounted externally on the center of the case.
• The TCM uses the intermediate shaft speed sensor information to aid in determining pressure requirements.
Pressure Control Solenoid A, Band C

• The pressure control solenoids are a variable-force style (VFS) solenoid. The VFS-type solenoid is an electro-
hydraulic actuator combining a solenoid and a regulating valve.
• The line pressure tap is used to verify output pressure from pressure control solenoid A or B by turning either
one off while verifying the output from the other solenoid.
• The second pressure tap is used to verify the output from the pressure control solenoid C.
• There are 3 pressure control solenoids located in the solenoid body assembly used to control line pressure,
band and clutch application pressure within the transmission.
• The TCM varies the current to the pressure control solenoid.
• The TCM has an adaptive learn strategy to electronically control the transmission which will automatically
adjust the shift feel. When the battery has been disconnected or a new battery installed, certain transmission
operating parameters may be lost. The TCM must relearn these parameters.
• During this learning process you may experience slightly firm shifts, delayed or early shifts. This operation is
considered normal and will not affect the function of the transmission. Normal operation will return once these
parameters are stored by the TCM.
Torque Converter Clutch (TCC) Control Solenoid

• The TCC control solenoid is a pulse width modulating type solenoid which is used to control the apply and
release of the TCC.
Shift Solenoid A, B, C and D

• Four ON/OFF shift solenoids allow the TCM to control shift scheduling.
- The solenoids are 3-way, normally open style.
- The shift solenoids shift solenoid A, B, C and D provide gear selection of 1GR through 5GR and REVERSE
gears by directing pressure control pressures to the appropriate elements.
• Coast braking and manual gears are also controlled by the shift solenoids.
Transmission Fluid Temperature (TFT) Sensor

• The TFT sensor is a thermistor-type sensor that varies a reference voltage signal. The resistance in the TFT
varies with temperature.
• The TCM monitors the voltage signal across the TFT and uses this information to determine the transmission
fluid temperature.
• The TFT is located on the solenoid body.
• The TCM uses the TFT signal to help determine shift scheduling, torque converter clutch operation and
pressure control requirements.
• It sends a voltage signal to the TCM. The voltage signal varies with transmission fluid temperature. The TCM
uses this signal to determine whether a cold start shift schedule is necessary. The shift schedule is
compensated when the transmission fluid temperature is cold. The TCM also inhibits TCC operation at low
transmission fluid temperatures and uses it to determine PC solenoid operations.
05-13-57
1 I
OIL COOLER CONSTRUCTION [5R55S]
id0513c1221500
• A water-coaling type AT oil cooler has been adopted and is installed in the radiator. The oil cooler cools the
heated ATF in the AT.
• An air-cooling type AT oil cooler has also adopted.
~
FRONT
RADIATOR
(IN TANK OIL COOLER)
OIL COOLER
.IIf
FRONT
AUTOMATIC
TRANSMISSION
arnffn00000398
05-13-58
AUTOMATIC TRANSMISSION SHIFT MECHANISM
05-14 AUTOMATIC TRANSMISSION SHIFT MECHANISM

AUTOMATIC TRANSMISSION AUTOMATIC TRANSMISSION
SHIFT MECHANISM OUTLINE . ...... 05-14-1 SHIFT MECHANISM
STRUCTURAL ViEW ............... 05-14-1
AUTOMATIC TRANSMISSION SHIFT MECHANISM OUTLINE

id051400219700
• The cable type shift mechanism has been adopted.
• The floor-shift type selector lever has been adopted.
AUTOMATIC TRANSMISSION SHIFT MECHANISM STRUCTURAL VIEW

id051400219800
,-j--_ _ SELECTOR
:['~~~~:--"'f"..c:--"/" LEVER
DIGITAL TR
SENSOR
SELECTOR CABLE
arnffn00000334
05-14-1
STEERING
OUTLINE ................. 06-00 POWER STEERING ......... 06-14
06-00 OUTLINE
STEERING ABBREVIATION •.......•. 06-00-1 STEERING SPECIFICATIONS .....•... 06-00-1
STEERING FEATURES .....••...•... 06-00-1
STEERING ABBREVIATION
dcf060000000t01
IATF IAutomatic Transmission Fluid

STEERING FEATURES
dcf06000000Ot02
Improved handling stability • Engine sp~ed sensing power steering adopted

Improved operability • Steering shaft with a tilt mechanism adopted (Some models)
Improved safety • Collapsible steering shaft adopted
STEERING SPECIFICATIONS
dcf06000000Ot03
Item Specification
380 {15.0} [with air bag],
Outer diameter (mm {in})
Steering wheel 390 {15.4} [without air bag]
Lock-to-Iock (turns) 3.7
Shaft type Collapsible
Steering column and
Joint type (mm {in}) Rubber coupling
shaft
Amount of tilt (mm {in}) 30 {1.2}
Steering gear and
Type Ball nut
linkage
Power assist type Engine speed sensing
Power steering Type ATF M-1I1 or equivalent (e.g. Dexron®II)
system Power steering fluid Fluid capacity*1 (approx quantity) 1.1 {1.2, 1.0}
(L {US qt, Imp qt})
*1 : When fluid reservoir is at maximum volume.
06-00-1
POWER STEERING
06-14 POWER STEERING

POWER STEERING OUTLINE ........ 06-14-1 STEERING GEAR AND LINKAGE
POWER STEERING STRUCTURAL CONSTRUCTION .................. 06-14-3
VIEW . .......................... 06-14-2 POWER STEERING OIL PUMP
CONSTRUCTION .................. 06-14-4
STEERING SHAFT CONSTRUCTION . . . 06-14-5
POWER STEERING OUTLINE

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

• The hydraulic pressure from the oil pump is transmitted to the cylinder part by the control valve according to the
operation of the steering wheel.
• The ball nut rotation resistance is reduced in proportion to the amount of the hydraulic pressure transmitted to
the cylinder part.
CONTROL VALVE
CYLINDER PART
PITMAN ARM
BALL NUT SECTOR SHAFT
DBR614ZTB002
06-14-3
POWER STEERING
POWER STEERING OIL PUMP CONSTRUCTION
dcf061432650t01
• The oil pump is driven through the crankshaft (timing gear), idle gear, and vacuum pump gear. As a result, a
lowering of performance due to belt slippage or breakage has been eliminated.
• A flow control valve which adjusts the amount of oil sent to the steering gear has been designed in the oil pump
to control hydraulic pressure fluctuation according to engine speed.
FLOW CONTROL VALVE

A
CAM RING
GEAR
ROTOR SHAFT
ROTOR
VANE
A'
DISCHARGE PORT
LOCATION PIN
CAM RING
ROTOR SHAFT
SUCTION
VANE
SUCTION PORT
ROTOR
DISCHARGE
SECTION A-A'
DBR614ZTB003
06-14-4
POWER STEERING
STEERING SHAFT CONSTRUCTION
dcf06143201Ot01
• Tilt steering has been optionally equipped to adjust the position of the steering wheel to suit the driver's
particular body shape and driving posture.
• The tilt system is adjustable by 30mm {1.2 in} in the up/down direction.
• A collapsible steering shaft has been adopted to minimize driver injury in the event of a frontal collision.
DBR614ZTB004
06-14-5
HEATER, VENTILATION &
AIR CONDITIONING (HVAC) 07
SECTION
OUTLINE . ................ 07-00 CONTROL SYSTEM . ....... . 07-40

BASIC SYSTEM . ........... 07-11
07-00 OUTLINE
HVAC ABBREVIATION . ............. 07-00-1 HVAC SPECIFICATIONS . ........... . 07-00-1
HVAC FEATURES . ................. 07-00-1
HVAC ABBREVIATION
dcf070000000to1
AlC Air Conditioning

B+ Battery Positive Voltage
DEF Defroster
HI High
LOW Low
M Motor
MAX Maximum
OFF Switch Off
ON Switch On
REC Recirculate
HVAC FEATURES
dcf070000000t02
Improved air conditioning

• Sub-cooling system to multi-flow condenser adopted
performance
HVAC SPECIFICATIONS
dcf070000000to3
Airflow volume
(during air conditioner Blower motor 450
operation)
Electricity
consumption (during
air conditioner (W) 48
operation)
Refrigerant
(g {oz}) 475 {16.8}
AlC compressor
180 {180, 6.08}
07-00-1
OUTLINE
Item Specification
Type Multiflow (sub-cooling type)
Radiated heat (kW {kcal/h}) 10.46 {8,996}
Condenser
Receiver/drier capacity (ml {cc, fl oz}) 220 {220, 7.44}
Desiccant Synthetic zeolite
Expansion valve Type Internal pressure equalizar
Evaporator Type Single-tank drawn cup
Type Dual-pressure type
Operating pressure
1 L------1
0.176-0.216 2.94-3.34
ON - - :1: ,.20, 25.<C6-31.2B, <;".D-34.0i"-483'
Refrigerant pressure
t
switch
(MPa {kgf/cm 2 , psi})
OFF ----me I • I •
I I • •
:f l: :' l:
0.02 {0.20, 2.B4} 0.39-0.79
or Jess {3.9B-B.05,57-114}
Fusible plug Melting point 102-107 {216-224}
07-00-2
BASIC SYSTEM
07-11 BASIC SYSTEM

BASIC SYSTEM LOCATION INDEX .••. 07-11-1 AlC COMPRESSOR
BLOWER UNIT CONSTRUCTION .................. 07-11-4
CONSTRUCTION/OPERATION ••.... 07-11-2 CONDENSER CONSTRUCTION .....•. 07-11-5
COOLING UNIT REFRIGERANT LINE
CONSTRUCTION/OPERATION ••.•.. 07-11-3 CONSTRUCTION •....••......••.•. 07-11-5
BASIC SYSTEM LOCATION INDEX

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

DBG711 ZTB005
Evaporator
• The evaporator vaporizes the refrigerant flowing
inside it. The latent heat of the vaporized EVAPORATOR
refrigerant cools the air passing through the
evaporator. At the same time, moisture in the air
condensates. In this way, dehumidified air is
supplied to the passenger compartment.
• The evaporator is a single tank drawn cup type.
Because refrigerant flows through several
separate tubes, flow path resistance is kept low
and the surface area for heat exchange is
increased, improving air conditioning efficiency. COOLING UNIT
EVAPORATOR
REFRIGERANT FLOW
DBG711ZTB006
07-11-3
BASIC SYSTEM
Expansion valve
• The expansion valve causes a sudden decrease
EVAPORATOR
in the pressure of the liquid refrigerant. This
atomizes the refrigerant, making it easier for the
evaporator to vaporize it. The expansion valve
also regulates the flow volume of the refrigerant EXPANSION VALVE --lI-+++H*C"/'c~
sent to the evaporator.
• An internal pressure equalizer expansion valve is
used. It regulates the flow volume of the
refrigerant supplied to the evaporator so that the
heat absorption process of the evaporator is
utilized efficiently.
EXPANSION VALVE
COLD, LOW-
PRESSURE, HOT, HIGH-
AND VAPOROUS PRESSURE,
REFRIGERANT AND LIQUID
REFRIGERANT
II
II
FROM
RECEIVER/DRIER
DBG711ZTB007
AlC COMPRESSOR CONSTRUCTION

dcf07116145ot01
• The A/C compressor compresses the low-pressure gaseous refrigerant vaporized from the evaporator into a
high-pressure gas so that the condenser can liquidize it more easily. A swash-plate of the NC compressor is
used to reduce weight and vibration and to improve driving performance when the A/C compressor is
operating.
• The NC compressor is belt-driven via the engine crankshaft pulley.
• Five double-acting pistons positioned axially around the compressor shaft are actuated by a swash plate that is
pressed onto the compressor shaft. The swash plate changes the rotating action of the. shaft to reciprocating
movement of the five pistons. This driving force is applied to the midpoint of each of the double-ended pistons.
DUBLE-ACTING PISTON
SUCTION DISCHARGE SUCTION DISCHARGE DISCHARGE SUCTION

-DISCHARGE -SUCTION
---- ..
I
I
---~
COMPRESSOR SHAFT
SWASH PLATE
DBG711 ZTB008
07-11-4
BASIC SYSTEM
CONDENSER CONSTRUCTION
dcf07116148ot01
• The receiver/drier, main condenser, and sub-
condenser are integrated into the sub-cooling RECEIVER/DRIER CONDENSER
system multi-flow condenser.
• The sub-cooling system multi-flow condenser
sends refrigerant cooled in the main condenser to
the receiver/drier and re-cools it in the sub-
condenser for a more efficient cooling process.
DBG711ZTB009
REFRIGERANT LINE CONSTRUCTION
dcf071161460t01
• Cooler pipes and cooler hoses are refrigerant passages.
• Refrigerant flows inside of each pipe and hose in the form of high-pressure gas from the A/C compressor to
condenser, in the form of high-pressure liquid from the condenser to the expansion valve, and in the from of
low-pressure gaseous from the expansion valve to the A/C compressor.
• The diameter of each pipe is different according to the state of the refrigerant.
LOW PRESSURE
GASEOUS
REFRIGERANT
HIGH-PRESSURE LIQUID
REFRIGERANT
DBG711 ZTB022
Piping Connection
• To prevent O-rings from falling off while piping
work is being performed, stay-on O-rings are
used at the piping connections.
DBG711 ZTB015
07-11-5
CONTROL SYSTEM
07-40 CONTROL SYSTEM

CONTROL SYSTEM OUTLINE ........ 07-40-1 MAGNETIC CLUTCH
CONTROL SYSTEM LOCATION CONSTRUCTION . ................ . 07-40-3
INDEX . ......................... 07-40-1 REFRIGERANT PRESSURE SWITCH
CONTROL SYSTEM WIRING CONSTRUCTION . ................ . 07-40-4
DIAGRAM .................... ... 07-40-2 CLIMATE CONTROL UNIT
BLOWER MOTOR CONSTRUCTION . .. 07-40-2 CONSTRUCTION . ................ . 07-40-4
RESISTOR CONSTRUCTION . ........ 07-40-3 MANUAL AIR CONDITIONER
CONTROL SYSTEM . .............. . 07-40-4
CONTROL SYSTEM OUTLINE

dcf074000000l01
IImproved operability I• Climate control unit with enlarged operation dial and switch adopted
CONTROL SYSTEM LOCATION INDEX

dcf07400000Qt02
REFRIGERANT PRESSURE
SWITCH
CLIMATE CONTROL UNIT
THERMOSWITCH
BLOWER MOTOR
07-40-1
CONTROL SYSTEM
CONTROL SYSTEM WIRING DIAGRAM
defO?400000Ot03
IG2 B+
IG2 IG2 IG2 B+
BLOWER
RELAY
NC RELAY
BLOWER
MOTOR
MAGNETIC
CLUTCH
THERMISTOR
FAN SWITCH AlC SWITCH AlC AMPLIFIER
DBG?40ZTB800
BLOWER MOTOR CONSTRUCTION

dcfO? 4061020101
• The blower motor rotates the blower fan to blow

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

motor, corresponding to fan switch operation. The
resistor controls the rotation speed (airflow
volume) in 4 stage.
RESISTOR IG2
BLOWER
MOTOR
1 2 3
4 FAN SWITCH
OFF
DBG?40ZTB010
MAGNETIC CLUTCH CONSTRUCTION

delO?406101 Otol
• A magnetic clutch drives the compressor shaft.

• When voltage is applied to the stator, the magnetic force locks the pressure plate and the pulley together as
one unit. As a result the compressor shaft then turns with the pulley.
• When voltage is removed from the stator, the pressure plate returns from the pulley by the rubber spring force.
As a result the the compressor shaft does not turn.
ro
SPRING~
RUBBER
AlC COMPRESSOR
PULLEY
SNAP RING
COMPRESSOR SHAFT
SNAP RING
PRESSURE PLATE
DBG?40ZTBOll
07-40-3
CONTROL SYSTEM
REFRIGERANT PRESSURE SWITCH CONSTRUCTION
dcf074061503to1
• The refrigerant pressure switch is fitted to the cooler pipe and senses the refrigerant pressure.
• A dual-pressure refrigerant pressure switch is used to respond to both abnormally high and abnormally low
pressures.
• When pressure is abnormal, the refrigerant pressure switch turns off and cuts the voltage sent from the
magnetic clutch, thereby stopping the AlC compressor.
IG2 B+
0.176-0.216 2.94-3.34
AlC
----r - - 1
{1.79-2.20,2S.46-31.28} {30.0-34.0, 427-483}
RELAY
OFF-mm~
ON
.
!,,!
L----..1
.
0.02 {0.20, 2.84}
. +. if
0.39-0.79
):
or less {3.98-8.0S, S7-114}
MPa {kgf/cm2, psi}
DBG740ZTB002
CLIMATE CONTROL UNIT CONSTRUCTION

dcf074061190101
• Each switches and dials have been enlarged to improve ease of operation.
AIRFLOW MODE
SELECTOR DIAL
TEMPERATURE
CONTROL DIAL
CLIMATE CONTROL
UNIT
REC/FRESH LEVER
DBG740ZTB012
MANUAL AIR CONDITIONER CONTROL SYSTEM

dcf074000005101
Block Diagram
• The fan switch and thermistor sends an AlC signal to the PCM via the AlC amplifer.
-.-
{~
PCM
FAN SWITCH AlCCUT

CONTROL
~ -.- AMPLIFIER AlC RELAY

REFRIGERANT AlC COMPRESSOR
PRESSURE
SWITCH
THERMISTOR
DBG740ZTB019
07-40-4
CONTROL SYSTEM
AlC Compressor Control
• The A/C signal from the thermistor and A/C amplifer controls the magnetic clutch via the PCM, AlC relay and
refrigerant pressure switch.
SIGNAL r-::-l
~
SIGNAL ~~AlC
Q AlC
--. L-.J--'
--.OPERATE
lL --.
AlC RELAY
REFRIGERANT AlC COMPRESSOR
THERMISTOR AlC PRESSURE
AMPLIFIER SWITCH
DBG740ZTB020
07-40-5
RESTRAINTS
OUTLINE ................. 08-00 AIR BAG SYSTEM .......... 08-10

ON-BOARD DIAGNOSTIC . ... 08-02 SEAT BELT ................ 08-11 ".
08-00 OUTLINE
RESTRAINTS ABBREViATIONS ...... 08-00-1 RESTRAINTS FEATURES . .......... . 08-00-1
RESTRAINTS ABBREVIATIONS
dcf080000000t01
DLC Data Link Connector

DTC Diagnostic Trouble Code
ELR Emergency Locking Retractor
GND Ground
SAS Sophisticated Air Bag Sensor
RESTRAINTS FEATURES
dcf08000000Ot02
• A driver-side air bag module has been adopted.

• A passenger-side air bag module has been adopted.
Improved safety
• A side air bag module has been adopted.
• A pre-tensioner seat belt has been adopted.
08-00-1
ON-BOARD DIAGNOSTIC

ON-BOARD DIAGNOSTIC FUNCTION ON-BOARD DIAGNOSTIC FUNCTION
OUTLINE •........•..••.......... 08-02-1 [AIR BAG SySTEM] ................ 08-02-1
ON-BOARD DIAGNOSTIC FUNCTION OUTLINE

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

dcf08020000Dt02
Self-Malfunction Diagnostic Function

• The self-diagnostic function determines that there is a malfunction, outputs a signal, as a DTC, to the DLC-2,
and at the same time, flashes the air bag system warning light to advise the driver of a malfunction.
• The air bag system warning light illuminates or flashes to indicate a single DTC according to the present
malfunction. (If there is more than one present malfunction, only one DTC will be displayed according to the
preset priority ranking.)
• The air bag system warning light will flash the DTC pattern for five cycles, and then will remain illuminated until
the engine switch is turned to the LOCK position.
• The self-diagnostic function consists of a present malfunction diagnostic and a past malfunction diagnostic.
DTC table
DTC
Current Air bag system warning light
diagnostic Malfunction location
tool
""
Priority
Flashing pattern
display ranking
~
SAS control module activation (deployment)
81231 13 3
control freeze
Air bag system warning light is illuminated all The SAS control module power supply voltage
81317 - the time.
-
increases (16.1 V or more)
Air bag system warning light is illuminated all The SAS control module power supply voltage
81318 - the time
-
decreases (less than 9 V)
81342
12
ULJ 2 SAS control module
Air bag system warning light is illuminated all SAS control module (DTC 12 detection circuit
- the time.
1
malfu nction)
Air bag system warning light is illuminated all
- 1 Air bag system warning light system circuit open
the time.
81869
Air bag system warning light is illuminated Air bag system warning light system circuit short
- does not illuminate.
-
to ground
Air bag system warning light is illuminated all Air bag system warning light system circuit short
81870 - 1
the time. to power supply
Driver-side pre-tensioner seat belt circuit
81877
resistance high
~
Driver-side pre-tensioner seat belt circuit short to
81878 33 10
power supply
Driver-side pre-tensioner seat belt circuit short to
81879 ground
08-02-1
ON-BOARD DIAGNOSTIC
DTC
tool Priority
Flashing pattern
display ranking
Passenger-side pre-tensioner seat belt circuit
81881 resistance high
81882
81883
34
1-- 9
short to power supply
short to ground
81885 33
JlflJLJl11JLJ 10
Driver-side pre-tensioner seat belt circuit
resistance low
81886 34
1-- 9
resistance low
81913
19
I JLJlJlJlJlJlflJ 8
Driver-side air bag module circuit short to body
ground
21
JULJ 7
Passenger-side air bag module circuit short to
body ground
81916 19
I JLJlJlJlJlJlflJ 8
Driver-side air bag module circuit short to power
supply
81925 21
JULJ 7
Passenger-side air bag module system circuit
short to power supply
81932 19
I JLJlJlJlJlJlflJ 8 Driver-side air bag module circuit resistance high
81933 21
JULJ 7
Passenger-side air bag module circuit resistance
high
81934 19
I JLJlJlJlJlJlflJ 8 Driver-side air bag module circuit resistance low
81935 21
JULJ 7
Passenger-side air bag module circuit resistance
low
Driver-side side air ba~ module circuit short to

81992 power supply
Driver-side side air bag module circuit short to
81993
~
ground
22 12
Driver-side side air bag module circuit resistance
81994 high
Driver-side side air bag module circuit resistance
81995 low
Passenger-side side air bag module circuit short
81996 to power supply
Passenger-side side air bag module circuit short
81997
81998
23
JULJlJ1LJ 11
to body ground
Passenger-side side air bag module circuit
resistance high
Passenger-side side air bag module circuit
81999 resistance low
08-02-2
ON-BOARD DIAGNOSTIC
OTC
tool Priority
Flashing pattern
display ranking
82228
82230
19 8 Driver-side air bag module assembly incorrect
82232
82234
82229
82231
1---=---------1 21 ~ 7
Passenger-side air bag module assembly
82233 incorrect
82235
Driver-side side air bag sensor system (internal

82444 6
circuit disabled)
Passenger-side side air bag sensor system

82445 5
(internal circuit disabled)
Poor connection of any SAS control module

82867 4
connectors
Driver-side side air bag sensor (communication

U2017 6
error)
Passenger-side side air bag sensor

U2018 5
(communication error)
PID/Data Monitoring Function

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

D_PTENSFLT OPEN • Related wiring harness circuit open: OPEN
(Driver-side pre-tensioner seat SHRT_8+ • Related wiring harness short to power supply: SHRT_8+ 2P,2S
belt circuit state) SHRT_GND • Related wiring harness short to ground: SHRT_GND
Normal • Related wiring harness normal: Normal
DA8AGR
(Driver-side air bag module ohm Under any condition: 1.5-3.7 ohm 1S,1V
resistance)
DR_PTENS
(Driver-side pre-tensioner seat ohm Under any condition: 1.5-3.1 ohm 2P,2S
belt resistance)
08-02-3
ON-BOARD DIAGNOSTIC

DS_AB
(Driver-side side air bag ohm Under any condition: 1.4-3.2 ohm 2M, 20
module resistance)
SHRT_B+ • Related wiring harness short to power supply: SHRT_B+
DS_AB_ST SHRT_GND • Related wiring harness short to ground: SHRT_GND
(Driver-side side air bag OPEN • Related wiring harness circuit open: OPEN 2M,20
module circuit state) SQ_LOWRES • Air bag module circuit resistance low: SQ_LOWRES
SHRT_GND • Related wiring harness short to ground: SHRT GND
DS1_STAT SHRT_B+ • Related wiring harness short to power supply: SHRT B+
(Driver-side air bag module OPEN • Related wiring harness circuit open: OPEN 1S,1V
circuit state) SQ_LOWRES • Air bag module circuit resistance low: SQ_LOWRES
DSB_P_ST
(On demand driver-side pre-
OPEN • Related wiring harness circuit open: OPEN
tensioner seat belt circuit
SHRT_B+ • Related wiring harness short to power supply: SHRT_B+ 2P,2S
state)
SHRT_GND • Related wiring harness short to ground: SHRT_GND
IG_V_2
V engine switch to ON position: B+ 1W
(System IG1 voltage value)
OD_CRST_D1
(On demand driver-side side OK! • Sensor normal: OK
2Z,2AA
air bag sensor communication FAULT • Sensor communication error: FAULT
state)
OD_CRST_D2
(On demand driver-side side
2Z,2AA
air bag sensor circuit state)
OD_CRST_P1
(On demand passenger-side OK! • Sensor normal: OK
2B,2C
side air bag sensor FAULT • Sensor communication error: FAULT
OD_CRST_P2
2B,2C
side air bag sensor circuit FAULT • Sensor internal circuit error: FAULT
state)
OD_DAB1_ST SHRT_B+ • Related wiring harness short to power supply: SHRT_B+
(On demand driver-side air OPEN • Related wiring harness circuit open: OPEN 1S,1V
bag module circuit state) SQ_LOWRES • Air bag module circuit resistance low: SQ_LOWRES
OD_DSAB_ST SHRT_GND • Related wiring harness short to ground: SHRT_GND
(On demand driver-side side OPEN • Related wiring harness circuit open: OPEN 2M,20
air bag circuit state) SQ_LOWRES • Air bag module circuit resistance low: SQ_LOWRES
OD_PAB1_ST SHRT_B+ • Related wiring harness short to power supply: SHRT_B+
j
(On demand passenger-side OPEN • Related wiring harness circuit open: OPEN 1M,1P
i
I,
air bag module circuit state) SQ_LOWRES
Nnrm",(
• Air bag module circuit resistance low: SQ_LOWRES
• n. lIirinn h",rnA"'''' nnrm",(' Normal
OD_PSAB_ST
SHRT~B+ • Related wiring harness short to power supply: SHRT_B+
(On demand passenger-side
side air bag sensor circuit
OPEN • Related wiring harness circuit open: OPEN 21,2L
state)
P_PTENSFLT OPEN • Related wiring harness circuit open: OPEN
(Passenger-side pre-tensioner SHRT_B+ • Related wiring harness short to power supply: SHRT_B+ 2G,2J
seat belt circuit state) SHRT_GND • Related wiring harness short to ground: SHRT_GND
PABAGR .\
(Passenger-side air bag ohm Under any condition: 1.4-2.9 ohm 1M,1P
module resistance)
PS_AB
, (Passenger-side side air bag ohm Under any condition: 1.4-3.2 ohm 21,2L
module resistance)
08-02-4
ON-BOARD DIAGNOSTIC

PS_AB_ST SHRT_GND • Related wiring harness short to ground: SHRT_GND
(Passenger-side side air bag OPEN • Related wiring harness circuit open: OPEN 21,2L
sensor circuit state) SQ_LOWRES • Air bag module circuit resistance low: SQ_LOWRES
PS_PTENS
(Passenger-side pre-tensioner ohm Under any condition: 1.5-3.1 ohm 2G,2J
seat belt resistance)
PS1_STAT SHRT_B+ • Related wiring harness short to power supply: SHRT_B+
(Passenger-side air bag OPEN • Related wiring harness circuit open: OPEN 1M,1P
PSB_P_ST
OPEN • Related wiring harness circuit open: OPEN
pre-tensioner seat belt circuit
SHRT_B+ • Related wiring harness short to power supply: SHRT_B+ 2G,2J
state)
08-02-5
i:.
AIR BAG SYSTEM
08-10 AIR BAG SYSTEM

AIR BAG SYSTEM OUTLINE ......... 08-10-1 DRIVER-SIDE AIR BAG MODULE
AIR BAG SYSTEM STRUCTURAL CONSTRUCTION/OPERATION . ..... . 08-10-5
VIEW . .......................... 08-10-2 PASSENGER-SIDE AIR BAG MODULE
AIR BAG SYSTEM FUNCTION . ..................... . 08-10-5
WIRING DIAGRAM ................ 08-10-2 PASSENGER-SIDE AIR BAG MODULE
SAS CONTROL MODULE CONSTRUCTION/OPERATION . ..... . 08-10-5
FUNCTION .. .................... 08-10-3 SIDE AIR BAG MODULE FUNCTION ... 08-10-5
SAS CONTROL MODULE SIDE AIR BAG MODULE
CONSTRUCTION/OPERATION ...... 08-10-3 CONSTRUCTION/OPERATION . ..... . 08-10-6
DRIVER-SIDE AIR BAG MODULE PRE-TENSIONER SEAT BELT
FUNCTION . ..................... 08-10-4 FUNCTION . ..................... . 08-10-6
PRE-TENSIONER SEAT BELT
CONSTRUCTION/OPERATION ....... 08-10-7
AIR BAG SYSTEM OUTLINE

dcf081000000to1
• The air bag system is a device that supplements the passenger restraint function of the seat belts. The air bag
system will not have the designed effect if the seat belts are not worn properly.
• The air bag system is composed of the following parts:
Item Outline
SAS control module • Recognizes actually equipped air bag module or pre-
tensioner seat belt based on module configuration.
• Detects degree of impact, converts to an electrical signal, and
sends the signal to the SAS control module. For operation,
Side air bag sensor refer to SAS control module, Air Bag Module and Pre-
tensioner Seat Belt Deployment Operation. (See 08-10-3
SAS CONTROL MODULE CONSTRUCTION/OPERATION)
Driver-side air bag module
Passenger-side air bag module
• Adopted to improve safety in frontal collisions.
Side air bag module • Chest-protection type side air bag module has been adopted.
Pre-tensioner seat belt • Piston-type pre-tensioner seat belt has been adopted.
08-10-1
AIR BAG SYSTEM
AIR BAG SYSTEM STRUCTURAL VIEW
dcf081000000t02
AIR BAG SYSTEM WARNING LIGHT
•• CLOCK SPRING
( .. "
~
,,~ DRIVER-SIDE AIR BAG
PASSENGER-SIDE MODULE
AIR BAG MODULE ~
SIDE AIR BAG MODULE
SIDE AIR BAG SENSOR ~

DCF810ZTB001
AIR BAG SYSTEM WIRING DIAGRAM

dcf081 000000103
CLOCK SPRING
POOR CONNECTION
DETECTOR BAR
I )-----{
~
~---1:::;:::;:~Afi\~:::;- DRIVER-SIDE
AIR BAG
1------1 ~--t:=~~:!.C::=---l MODULE
DRIVER-SIDE PRE-
TENSIONER SEAT
AIR BAG
SYSTEM
r------1,!:l..C:=--1 BELT
SAS
WARNING
LIGHT .;1---+--+---[ CONTROL
MODULE DRIVER-SIDE SIDE
r----f,§l:=:::.J AIR BAG MODULE
PRE-TENSIONER SEAT
BELT
TWISTED PAIR
,_ ................. ...
DRIVER-SIDE A
SIDE AIR BAG PASSENGER-SIDE SIDE
SENSOR B AIR BAG MODULE
r--~:::::::..J
1--------
PASSENGER-SIDE A
SIDE AIR BAG
POOR CONNECTION
SENSOR B I ................. _
TWISTED PAIR I DETECTOR BAR
i,.
DCF810ZWB001
08-10-2
AIR BAG SYSTEM
SAS CONTROL MODULE FUNCTION
dcf08105703Ot01
Outline
Sensing function
• Safing and the crush sensors are built into the SAS control module.
• If the degree of impact detected by the safing and the crush sensors exceeds the set value during a collision,
the SAS control module sends an operation (deployment) signal to the air bag module and the pre-tensioner
seat belt.
Backup power supply function

• The backup power supply function enables the condenser to discharge and supply power to assure air bag
system operation/deployment properly for a specified time even if the power supply to the SAS control module
is cut due to a collision.
SAS CONTROL MODULE CONSTRUCTION/OPERATION

dcf08105703Ot02
Air Bag System
1. The impact of a frontal or frontal offset collision to the vehicle is transmitted to the SAS control module.
2. The safing sensor inside the SAS control module detects the collision and activates. In !addition, the crash
sensor determines the impact and converts it to an electronic signal and outputs it to the output control circuit.
SAS CONTROL MODULE
SAFING AIR BAG MODULE (DRIVER

SENSOR OR PASSENGER-SIDE AIR
BAG MODULE)
OUTPUT
CONTROL
CIRCUIT
-
(DRIVER OR PASSENGER-
SIDE)
I~
DCF810ZTB002
3. The output control circuit calculates the electronic signals from the crash sensor and the valve is compared with
the preset valve. If the output signal received from the crash sensors exceeds the preset value, an ignition
circuit is completed and an operation (deployment) signal is sent to both the driver and passenger-side air bag
modules.
08-10-3
AIR BAG SYSTEM
4. In conjunction with both the driver and passenger-side air bag module deployment, an ignition circuit for the
pre-tensioner seat belt is completed and an operation (deployment) signal is sent to the pre-tensioner seat belt.
SAS CONTROL MODULE
,..
j
f
I 0
IL I;>_ . ~ AIR BAG MODULE (DRIVER
SAFING
~ SENSOR
-- - - - I~
- - -
OR PASSENGER-SIDE AIR
BAG MODULE)
OUTPUT
CONTROL
~~,..
CIRCUIT I 0
IL I;>_
--
_ _ _ ~ PRE-TENSIONER SEAT BELT
_ __ I (DRIVER OR PASSENGER-
~ CRASH 1- SIDE)
I
~,
SENSOR
V'
DCF810ZTB003
Side air bag system

1. During a lateral collision to the vehicle, the crash sensors in the side air bag sensor and SAS control module
detect the collision.
2. The degree of impact detected by the crash sensor in the side air bag sensor is converted to an electrical signal
and sent to the SAS control module through the signal amplification circuit.
3. Simultaneously, the SAS control module crash sensor converts the degree of impact detected to an electrical
signal.
4. The SAS control module processes the calculations for the two electrical signals at the output control circuit
and compares the value to a preset value.
5. The output control circuit determines the degree of impact to the vehicle by the value from the crash sensors,
completes a side air bag module ignition circuit, and sends the deployment signal to the air bag modules.
SIDE AIR BAG SENSOR SAS CONTROL MODULE
ICRASH I
SENSOR
'-r-
SIGNAL
AMPLIFICATION
CIRCUIT 119
L _ ~
-_ -_ -_I ~ SIDE AIR BAG MODULE
I
CRASH
SENSOR
. ~~
OUTPUT CONTROL--
V
CIRCUIT
V'
DCF810ZTB004
DRIVER-SIDE AIR BAG MODULE FUNCTION

dcf081 05701 ot01
Outline
• During a frontal or front offset collision, an operation signal from the SAS control module is received and the
front air bag operates (deploys), softening the impact to the head and face areas of the driver.
08-10-4
AIR BAG SYSTEM
DRIVER-SIDE AIR BAG MODULE CONSTRUCTION/OPERATION
dcf081 05701 ot02
• Installed in the center of the steering wheel.

• The inflator operates in the following order.
Inflator Operation
1. When an operation (deployment) signal is received from the SAS control module, the igniter built into the
inflator generates heat and ignites the ignition agent.
2. The ignition of the ignition agent causes the combustion of a gas generating agent which forms nitrogen gas.
3. The nitrogen gas is cooled at the filter and the filtrate is injected into the air bag.
IGNITION OF
GAS GAS GENERATING
GAS INFLATION NITROGEN
GENERATION AGENT COMBUSTION
GENERATION AGENT
AGENT GAS
AGENT
IGNITOR FILTER FILTER
DCF810ZTB005
PASSENGER-SIDE AIR BAG MODULE FUNCTION

dcf08105705ot01
Outline
• During a frontal or front offset collision, an operation signal from the SAS control module is received and the air
bag operates (deploys), softening the impact to the head and face areas of the front passenger.
PASSENGER-SIDE AIR BAG MODULE CONSTRUCTION/OPERATION

dcf08105705ot02
• Installed in the dashboard.

• The inflator operation is the same as the driver's side air bag. (See 08-10-5 DRIVER-SIDE AIR BAG MODULE
CONSTRUCTION/OPERATION.)
SIDE AIR BAG MODULE FUNCTION

dcf081 000147101
• During a collision to the side of the vehicle, the air bag operates (deploys) after receiving an operation signal
from the SAS unit, defusing impact to the chest area of the driver and front passenger.
08-10-5
AIR BAG SYSTEM
SIDE AIR BAG MODULE CONSTRUCTION/OPERATION
dcf081000147to3
Construction
• Side air bag modules are installed on the outboard sides of the seat backs.
• The side air bag module is composed of an inflator, module cover and air bag.
• When an air bag deploys, the side air bag module cover is spread apart by the generation of argon gas from
the inflator, inflating the air bag.
MODULE
COVER
AIR BAG
DCF810ZTB006
Operation
Air bag module deployment operation
• Refer to the SAS control module, Air Bag Module and Pre-tensioner Seat Belt Deployment Operation. (See 08-
10-3 SAS CONTROL MODULE CONSTRUCTION/OPERATION.)
Inflator operation
1. The igniter built into the inflator begins to build up heat when the operation (deployment) signal is sent from the
SAS control module. The inflation agent is ignited by the build up of heat in the igniter.
2. The argon gas expands due to the heat of the ignited inflation agent.
3. The expanding argon gas breaks the discharge barrier, is cooled and filtered by the filter, and then injected into
the air bag.
ARGON GAS EXPANSION
INFLATION AGENT ARGON GAS
/ \\ ~~~IR
m~~-1----===1(====!1====='--J~ +~ V~
\
IGNITOR COMBUSTION OF
/
c:::::> ~+~ t )'====i1ijr~
- ~ ~~OAIR
DISCHARGE BARRIER BAG
INFLATION AGENT
EPU810ZT3006
PRE·TENSIONER SEAT BELT FUNCTION

dcf08105763ot01
• When a vehicle is involved in a frontal or frontal offset collision and the seat belts are buckled, the pre-tensioner
seat belt system receives an operation signal from the SAS control module, retracting and tightening the belt
webbing instantly on the driver and passenger restraints.
08-10-6
AIR BAG SYSTEM
PRE-TENSIONER SEAT BELT CONSTRUCTION/OPERATION
dcf08105763Ot02
Construction
SPRING SEAT
A
SPINDLE ~
BASE
PISTON
CAP NUT
GAS GENERATOR
CYLINDER
EPU810ZT3011
08-10-7
AIR BAG SYSTEM
Operation
Normal (Seat Belt Pretensioners Not Operating)
• Normally, the clutch roller installed to the outer circumference of the spindle sits in the recess of the gear and
does not interfere with the spindle .
• The gear does not rotate when the belt is pulled or retracted because the spindle and gear are not engaged.
lr-+---GEAR
SPINDLE
CLUTCH ROLLER
EPU810ZT3012
Seat Belt Pretensioners Operating

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

SEAT BELT OUTLINE ............... 08-11-1 LOAD LIMITER RETRACTOR
SEAT BELT STRUCTURAL ViEW ..... 08-11-1 CONSTRUCTION/OPERATION . ..... . 08-11-1
SEAT BELT OUTLINE

dcf08115700Dt01
Features
Improved safety • Three-point seat belt with the following functions for driver and passeger seat adopted
- ELR (Emergency Locking Retractor: emergency locking mechanism)
- Pre-tensioner seat belt (vehicle with pre-tensioner seat belt) (See 08-10-7
PRE-TENSIONER SEAT BELT CONSTRUCTION/OPERATION.)
- Load limiter, which adjusts restraint force of the seat belt to reduce the possibility of injury
to passengers caused by excess seat belt pressure after pre-tensioner operation. (vehicle
with pre-tensioner seat belt)
• Three-point seat belt with the following functions for rear seat passengers adopted (Double
cab)
-ELR
SEAT BELT STRUCTURAL VIEW

dcf081157000t02
BENCH SEAT
DCF811ZTB001
LOAD LIMITER RETRACTOR CONSTRUCTION/OPERATION

1. Initial state
CPJ811ZNB004
08-11-1
SEAT BELT
2. ELR operation
When the force of impact is transfered to the belt,
the retractor changes to the ELR condition,
locking the belt and securing the passenger's
body.
THE VEHICLE IS
INVOLVED IN AN IMPACT
DCF811ZTB002
3. Load limiter operation

After locking, if the force of impact transferred to
the belt is strong enough to cause injury to the
chest of the occupant, an adequate amount of
belt is released to absorb the load applied to the
chest.
CPJ811ZNB006
08-11-2
BODY & ACCESSORIES
OUTLINE ................. 09-00 INTERIOR TRIM ............ 09-17

BODY PANELS ............ 09-10 LIGHTING SYSTEMS ........ 09-18
GLASSIWINDOWS/ WIPERIWASHER SYSTEM ... 09-19
MIRRORS ............... 09-12 ENTERTAINMENT .......... 09-20
SEATS ................... 09-13 POWER SYSTEMS .......... 09-21
SECURITY AND LOCKS ..... 09-14 INSTRUMENTATION/DRIVER
EXTERIOR TRIM. . . . . . . . . . . 09-16 INFO..................... 09-22
09-00 OUTLINE
BODY AND ACCESSORIES BODY AND ACCESSORIES
ABBREVIATIONS . ................ 09-00-1 FEATURES . ..................... . 09-00-1
BODY AND ACCESSORIES ABBREVIATIONS

dcf09000000Dt01
4W-ABS 4-Wheel Antilock Brake System

ACC Accessories
ALC Auto Level Control
CM Control Module
GND Ground
HI High
HU Hydraulic Unit
IG Ignition
INT Intermittent
LCD Liquid Crystal Display
LED Light Emitting Diode
LH Left Hand
LO Low
M Motor
OFF Switch Off
ON Switch On
PCM Powertrain Control Module
RFW Remote Free Wheel
RH Right Hand
SW Switch
TNS Tail Number Side Lights
BODY AND ACCESSORIES FEATURES
• Power window system adopted

Improved marketability • Power door lock system adopted
• Keyless entry system adopted
• Immobilizer system adopted
Improved security
• Theft-deterrent system adopted
• A center panel unit, composed of the installed audio unit and the audio switches built into
Improved convenience
the center panel, has been adopted
09-00-1
BODY PANELS
09-10 BODY PANELS

BODY PANEL OUTLINE ............. 09-10-1 BODY PANEL STRUCTURAL VIEW .... 09-10-1
BODY PANEL OUTLINE

dcf091 0561 00t01
• Front and Rear Bumper has been changed.
BODY PANEL STRUCTURAL VIEW

dcf091 0561 OOt02
REAR BUMPER
FRONT BUMPER
DBG910ZTB001
09-10-1
I I
GLASSIWINDOWS/MIRRORS
09-12 GLASSIWINDOWS/MIRRORS
REAR WINDOW DEFROSTER POWER WINDOW SYSTEM
OUTLINE .............•...•.••... 09-12-1 WIRING DIAGRAM ••.••.•••........ 09-12-3
REAR WINDOW DEFROSTER POWER WINDOW SYSTEM
STRUCTURAL ViEW .............. 09-12-1 OPERATION •.••........•...•....• 09-12-3
REAR WINDOW DEFROSTER SYSTEM POWER OUTER MIRROR OUTLINE .... 09-12-3
WIRING DIAGRAM •.•.••...•..•... 09-12-1 POWER OUTER MIRROR
REAR WINDOW DEFROSTER SYSTEM STRUCTURAL ViEW .•........•...• 09-12-4
OPERATION ....•..............•. 09-12-2 POWER OUTER MIRROR SYSTEM
POWER WINDOW SYSTEM OUTLINE .. 09-12-2 WIRING DIAGRAM .....•.•......... 09-12-4
POWER WINDOW SYSTEM POWER OUTER MIRROR
STRUCTURAL ViEW ............•. 09-12-2 OPERATION .•...•...•...•........ 09-12-5
REAR WINDOW DEFROSTER OUTLINE

dcf09126300Ot01
• Rear window defroster system has been adopted.
REAR WINDOW DEFROSTER STRUCTURAL VIEW

dcf09126300Ot02
REAR DEFROSTER SWITCH
FILAMENT
DBR912ZT2001
REAR WINDOW DEFROSTER SYSTEM WIRING DIAGRAM

dcf091263000t03
REAR WINDOW
DEFROSTER RELAY
REAR WINDOW
DEFROSTER SWITCH FILAMENT
DBG912ZTB451
09-12-1
REAR WINDOW DEFROSTER SYSTEM OPERATION
dcf09126300Ot04
• When the rear window defroster switch is pressed, the rear window defroster turns on.
• Fogging is cleared from the rear window and outer mirror glass by heating of the filament.
• If the rear window defroster switch is pressed again with the rear window defroster on, defrosting will stop.
Defroster operation also stops if the engine switch is turned to LOCK while the system is operating
POWER WINDOW SYSTEM OUTLINE

dcf09125800Ot07
• The following functions have been adopted for all windows.

- Manual open/close function
- Auto-open function
• A power-cut function that permits disabling the operation of all window switches from the driver's seat has been
adopted.
POWER WINDOW SYSTEM STRUCTURAL VIEW

dcf09125800Ot02
POWER WINDOW
MAIN SWITCH
POWER WINDOW
SUBSWITCH
(PASSENGER'S SIDE)
DBR912ZT2002
09-12-2
POWER WINDOW SYSTEM WIRING DIAGRAM
dcf091258000t03
MANUAL MANUAL AUTO

CLOSE OPEN
POWER-CU
SWITCH
CLOSE/ CLOSE/ CLOSE/

OPEN OPEN OPEN
PfWl------f---H-,
eM
Passenger's side Rear right Rear left
DCF912ZT2001
POWER WINDOW SYSTEM OPERATION

dcf091258000t06
Manual Open/Close
• The window opens/closes according to the down (push) or up (pull) operation of the power window main
switches and the power window subswitches_
Auto-Open
• The window automatically moves to a fully-opened position when the power window main switches is operated
to fully open positions, either down (push)_
POWER OUTER MIRROR OUTLINE

dcf09126910Dt01
IImproved convenience I • Power outer mirror (mirror glass adjusting function) adopted
09-12-3
POWER OUTER MIRROR STRUCTURAL VIEW
dcf091269100t02
POWER OUTER
MIRROR SWITCH
DBR912ZT2004
POWER OUTER MIRROR SYSTEM WIRING DIAGRAM

dcf09126910Ot03
----------------------------
ACC RETRACT/RETURN RETRACT/RETURN
......... MOTOR (LH) MOTOR (RH)
P
POWER OUTER
MIRROR (LH)
POWER OUTER
MIRROR (RH)
RETURN RETRACT
..... ... ...
RETURN RETRACT
.....
~ ~
RIGHT........ LEFT
M
UP
t
-"W
RIGHT..... "'LEFT M
UP
t r®- r®-
~ ~
DOWN DOWN
r--
LEr DOVr
j 0\ 0\
boo
I :I ~I
e)1
L~ ~GHT
SIDE ( SIDE
L'EF:P ~HT
SIDE ( ) SIDE (
9
0
RETURN;(~
0
RETRACT
RETl!JRN
I
RETRACT
I
UP RIGHT
bI
I
DOWN; I ~I ~I
I
I
RIGlfT LEFt
UP
1
I
I
I
I
I
I
I
I
I
I
POWER OUTER MIRROR SWITCH I

----------------------------
WITH RETURN/RETRACT
?iT
DBR912ZT2005
09-12-4
POWER OUTER MIRROR OPERATION
dcf09126910Qt04
Mirror Glass Adjustment

• The left/right selection switch establishes left or right side outer mirror circuit and current is supplied in either
one of the four directions according to the position of the mirror glass adjustment switch. Due to this, the motor
rotates either up or down, left or right.
LEFT SIDE OUTER MIRROR IS
MOVED UPWARD UP/DOWN
ADJUSTMENT
ACC /MOTOR
.........
POWER OUTER
P MIRROR (LH)
-'M"-
UP
t V -'M"-
M
-
;--
•
I
r- RIGHT DO N ~
LE~I:© ~~ LEFT l~HT LEFT ~HT

SIDE ( ) SIDE
-I-
DOWN~ I ~up RIGH)
I
I J,0 I LEFT
.....
POWER OUTER MIRROR SWITCH
7} 'r
E5U912ZS5007
09-12-5
SEATS
09-13 SEATS
SEATS OUTLINE . .................. 09-13-1 SEATS STRUCTURAL ViEW .......... 09-13-2
SEATS SPECIFICATION . ............ 09-13-1
SEATS OUTLINE
dcf091357000l01
FEATURES
Improved marketability • Two types of have been adopted for the driver and passenger seats.
- Separate type
- Bench type
SEATS SPECIFICATION
dcf091357000l02
Body type Item Function

Stretch cab Seat Recliner
Slide
Side air bag module (See 08-10-5 SIDE AIR BAG MODULE FUNCTION.)
Regular cab Seat Recliner
Slide
Armrest
Double cab Front seat Recliner
Slide
Side air bag module (See 08-10-5 SIDE AIR BAG MODULE FUNCTION.)
Rear seat Armrest
09-13-1
SEATS
SEATS STRUCTURAL VIEW
dcf091357000t03
STRETCH CAB
(WITH REAR ACCESS SYSTEM) REGULAR CAB
DOUBLE CAB
REAR SEAT
FRONT SEAT
DCF913ZTB003
09-13-2
SECURITY AND LOCKS
09-14 SECURITY AND LOCKS

SECURITY AND LOCKS OUTLINE . ... 09-14-1 THEFT-DETERRENT SYSTEM
KEYLESS ENTRY SYSTEM INPUT/OUTPUT DIAGRAM .......... 09-14-4
OUTLINE ... ..................... 09-14-1 THEFT-DETERRENT SYSTEM
KEYLESS ENTRY SYSTEM CONDITION ...................... 09-14-4
STRUCTURAL VIEW . ............. 09-14-1 THEFT-DETERRENT SYSTEM
KEYLESS ENTRY SYSTEM PHASE .......................... 09-14-5
WIRING DIAGRAM ................ 09-14-2 IMMOBILIZER SYSTEM OUTLINE . ... . 09-14-7
KEYLESS ENTRY SYSTEM IMMOBILIZER SYSTEM STRUCTURAL
OPERATION ..................... 09-14-2 ViEW ............................ 09-14-8
THEF~DETERRENTSYSTEM IMMOBILIZER SYSTEM
OUTLINE .. ...................... 09-14-2 WIRING DIAGRAM ................. 09-14-8
THEFT-DETERRENT SYSTEM IMMOBILIZER SYSTEM SYSTEM
STRUCTURAL ViEW .............. 09-14-3 COMPONENT . ................... . 09-14-9
THEFT-DETERRENT SYSTEM IMMOBILIZER SYSTEM OPERATION ... 09-14-10
SYSTEM WIRING DIAGRAM ........ 09-14-3 ON-BOARD DIAGNOSTIC SYSTEM
[IMMOBILIZER SYSTEM] .......... . 09-14-11
SECURITY AND LOCKS OUTLINE

dcf091400001t01
Improved marketability • Power door lock system adopted

• Keyless entry system adopted
Improved security • Theft-deterrent system adopted
• Immobilizer system adopted
KEYLESS ENTRY SYSTEM OUTLINE

dcf09146600Dt01
• The doors also can be locked/unlocked by operating the key or transmitter.

• The answer-back function has been adopted where the hazard warning lights flash and a buzzer sounds to
confirm that the doors are locked/unlocked.
• A rolling code type transmitter has been adopted to prevent theft by radiowave interception.
• To prevent improper operation while the vehicle is moving, the doors cannot be locked/unlocked by operating
the transmitter if the ignition key is not in the LOCK position.
KEYLESS ENTRY SYSTEM STRUCTURAL VIEW

dcf09146600Dt02
REAR DOOR FRONT DOOR

FRONT DOOR LOCK ACTUATOR LOCK ACTUATOR
LOCK ACTUATOR
FLASHER CONTROL
MODULE
DOOR LOCK
CONTROL MODULE
TRANSMITIER
KEYLESS CONTROL
MODULE
DFC914ZWZ001
09-14-1
SECURITY AND LOCKS
KEYLESS ENTRY SYSTEM WIRING DIAGRAM
dcf09146600ot03
8+ IG1
KEYLESS ! •
CONTROL 8+
MODULE
DOOR LOCK
CONTROL MODULE
DOOR
SWITCH
HAZARD
WARNING
SWITCH
THEFT-DETERRENT
CONTROL MODULE
DBR914ZWB002
KEYLESS ENTRY SYSTEM OPERATION

dcf091466000t04
• When the transmitter LOCK/UNLOCK button is pushed, all doors lock/unlock.

• In response to transmitter operation (lock/unlock), the hazard warning lights flash to enable visual verification of
operation.
- When the transmitter LOCK button is pushed, the hazard warning lights flash once.
- When the transmitter UNLOCK button is pushed, the hazard warning lights flash twice.
• When any door is not opened within 30 s after the transmitter UNLOCK button is pressed, the UNLOCK signal
is cancelled and the doors are locked.
THEFT-DETERRENT SYSTEM OUTLINE

dcf09145000ot01
• The theft-deterrent system includes sound and light alarms that activate when the bonnet or a door is opened
by means other than the key. The turn lights flash and the theft-deterrent horn sounds. When the key is inserted
into the door key cylinder and turned to unlock, the warnings stop.
09-14-2
SECURITY AND LOCKS
THEFT-DETERRENT SYSTEM STRUCTURAL VIEW
dcf09145000Ot02
FRONT DOOR REAR DOOR

THEFT-DETERRENT LATCH AND LOCK LATCH AND LOCK
CONTROL MODULE ACTUATOR ACTUATOR FRONT DOOR
LATCH AND LOCK
ACTUATOR
BONNET SWITCH
DBR914ZTB006
THEFT-DETERRENT SYSTEM SYSTEM WIRING DIAGRAM

dcf09145000Ot03
B+ B+ INSTRUMENT B+
CLUSTER
DOOR AJAR
WARNING
LIGHT
KEY REMINDER
SWITCH SECURITY
FLASHER LIGHT
UNIT
HAZARD WARNING
SWITCH
THEFT-DETERRENT DRIVER'S DOOR

KEYLESS CONTROL MODULE LOCK-LINK
CONTROL SWITCH
MODULE
DOOR LOCK
CONTROL r-~---'----~---;
MODULE
BONNET
l. SWITCH
DOOR KEY B+
CYLINDER
SWITCH
THEFT-
DETERRENT
HORN
DFC914ZTB111
09-14-3
SECURITY AND LOCKS
THEFT-DETERRENT SYSTEM INPUT/OUTPUT DIAGRAM
dcf091450000to4
INPUT OUTPUT
KEY REMINDER
SWITCH ...
.
ENGINE SWITCH ~
SECURITY
..
LIGHT
I DOOR SWITCH
I
BONNET
SWITCH ~
THEFT-DETERRENT
CONTROL MODULE
.. I TURN LIGHT
I
DOOR KEY
CYLINDER SWITCH
(DRIVER'S SIDE)
THEFT-DETERRENT
DOOR KEY ... HORN
CYLINDER SWITCH
(PASSENGER'S SIDE)
DOOR LOCK-LINK
SWITCH
.....
DBR914ZWB003
THEFT-DETERRENT SYSTEM CONDITION

dcf091450000t05
Prearming Prearming
System phase Dead Initial Arming Alarm 1 Alarm 2
1 2
Timer period - - - - - *1 -
Key reminder On
switch (at least
Off Off Off Off - -
Engine switch one is on) Off Off Off Off On or Off
Door switch - Off On On or Off On or Off
On or Off
(at least Unlock
INPUT Bonnet switch - Off Off (at least On or Off
one is on) (at least one is on)
Door lock-link one is on or
switch
- - -
lock) Off On or Off
Driver's and
passenger's door
key cylinder
- - - - Off/Lock Off/Lock Off/Lock
switch
Theft-deterrent
Off Off Off Off Off Off
horn
OUTPUT
Turn light Off Off Off Off Off Off
Security light Off Off Off Off Off Off
*1: Theft-deterrent horn timer period is 25 s. Turn light timer period is 4.5 min.
09-14-4
SECURITY AND LOCKS
THEFT-DETERRENT SYSTEM PHASE
dcf09145000Dt06
Dead
• The condition before the key is removed from the steering lock. (The key is at either ON position, ACC position,
or LOCK position.)
• The security light is not lit at this time.
Initial
• The condition after the key is removed from the steering lock (with all doors and the bonnet closed).
ZBR8120W004
Prearming 1
• The key is removed from the steering lock and a door or a bonnet is open.
ZBR8120W005
Prearming 2
• The key is removed from the steering lock and a door is opened or not locked, and the bonnet is opened.
ZBR8120W006
09-14-5
SECURITY AND LOCKS
Arming 1
• The doors are locked with the key after all doors and the bonnet are closed.
• The turn lights have been flashed for 2 s shifting to "Arming 1" phase from "Prearming 2" phase.
• The security light is flashes at an interval of 3 s. The alarm system is fully set.
SECOND
DBR914ZWB004
Alarm 1
• A door or the bonnet is opened without using the key, or the ignition circuit is short-circuited. The theft-deterrent
horn sounds intermittently for 25 s and the turn lights flash intermittently for 4.5 min.
• The theft-deterrent horn sounds intermittently for 25 s and turn lights flash intermittently for 4.5 min again when
a door or the bonnet is opened or closed without using the key from the period of 25 s until 4.5 min.
ZBRB120WOOB
Alarm 2
• The condition (after 4.5 min have passed from the time "Alarm 1" phase was activated) in which the warning
system is deactivated.
• When the door or the bonnet is opened again, the condition returns to "Alarm 1" phase.
ZBRB120W009
09-14-6
SECURITY AND LOCKS
Alarm Stop Phase (Initial)
• The warning system is cancelled and the condition returns to "Initial" phase when either front door is unlocked
with the key.
ZBR8120W010
IMMOBILIZER SYSTEM OUTLINE

dcf09146700Ot01
• The immobilizer system prevents the engine from starting even if the engine switch is short-circuited. As a
result, it keeps the vehicle from being stolen.
• The system is composed of a special key, the security light, the coil, the immobilizer unit, and PCM. The engine
can be started using the key, which has an ID number registered in its transponder and which uses an
algorithmic verification method.
• The code word is input to the immobilizer unit and PCM. The vehicle dose not start if the code word is not newly
input when parts are replaced.
• The procedure for registering the ID number and the procedure for inputting the code word are different
according to the parts being replaced and the number of the registered keys.
09-14-7
SECURITY AND LOCKS
IMMOBILIZER SYSTEM STRUCTURAL VIEW
dcf091467000to2
SECURITY LIGHT KEY
PCM
DBR914ZWB005
IMMOBILIZER SYSTEM WIRING DIAGRAM

dcf091467000to3
B+ IG1 IG1 B+
SECURITY
1
LIGHT
STARTER
RELAY
COIL
PCM
DBR914ZTB007
09-14-8
SECURITY AND LOCKS
IMMOBILIZER SYSTEM SYSTEM COMPONENT
dcf091467000t04
Key
• The transponder in the key has a registered 10
number.
TRANSPONDER
DBR914ZTB008
Coil
• The coil is located in the steering lock.
• The coil has an antenna function and sends the STEERING
10 number to the immobilizer unit. COIL LOCK
DBR914ZTB009
Immobilizer Unit
• The immobilizer unit compares the 10 number and the algorithmic verification method of the key with those of
the immobilizer unit.
• When the 10 number and the algorithmic verification method are correct, the immobilizer unit sends the code
word to the peM
• When there is a malfunction in the immobilizer system, the immobilizer unit flashes the security light.
09-14-9
SECURITY AND LOCKS
IMMOBILIZER SYSTEM OPERATION
dcf091467000to5
• This is a conceptual flow chart for understanding how the immobilizer system operates. It shows how the
system decides whether or not to start the vehicle when the engine switch is turned to ON position.
Insert the key into the key cylinder. (Key reminder switch ON) I
•t
Coil reads the ID number of the key and sends it to the immobilizer unit. I
Immobilizer unit compares the ID number of the key with .that of the immobilizer unit. I
ID number agreement liD number disagreement
Starter relay ON
t
Turn ignition switch to ON position. I
I I
Immobilizer unit sends unlock Immobilizer unit sends lock
signal and code word to the signal to the PCM.
+
PCM.
I Engine can not be start I

PCM compares the code word of
the immobilizer unit with that of
the PCM.
t
I Security light start flashing I
Code word disagreement
Code word agreement
Security light illuminates

for 1 - 2 seconds. I Engine can not be start I
t
Engine will start I Security light start flashing I
DBR914ZTC001
09-14-10
SECURITY AND LOCKS
ON-BOARD DIAGNOSTIC SYSTEM [IMMOBILIZER SYSTEM]
dcf091467000t06
Outline
• If the immobilizer system has a malfunction, the on-board diagnostic system displays the diagnostic trouble
code number by flashing the security light when the engine switch is at ON position.
DTCTable
DTC Output pattern Description
01 ] I 10 number unregistered in immobilizer unit is input after engine

switch is turned to ON position or cranking engine.
02
Jl1l I 10 number format error (voltage range, frequency)
~
10 number is not input into immobilizer unit after engine switch is
03 turned to ON position or cranking engine.
11
JlJLJ Coil or wiring harness between immobilizer unit and coil is open
circuit.
~
Code word/lO number stored in immobilizer unit EEPROM cannot
21 be read.
~
Open or short circuit in wiring harness between immobilizer unit
24 and PCM.
30
mrLJ PCM is defective. (Malfunction of communication line inside PCM)
09-14-11
EXTERIOR TRIM
09-16 EXTERIOR TRIM

EXTERIOR TRIM OUTLINE . ......... 09-16-1 EXTERIOR TRIM STRUCTURAL
VIEW . .......................... . 09-16-1
EXTERIOR TRIM OUTLINE

dcf091600000t01
• Front and rear flaps have been adopted.

• Over fender has been adopted.
• Rope hook has been adopted.
EXTERIOR TRIM STRUCTURAL VIEW

dcf09160000Dt02
ROPE HOOK
REAR FLAP
DCG916ZTBOOO
09-16-1
INTERIOR TRIM
09-17 INTERIOR TRIM

INTERIOR TRIM OUTLINE ........... 09-17-1 INTERIOR TRIM STRUCTURAL VIEW .. 09-17-1
INTERIOR TRIM OUTLINE

dcf091755000to1
• Glove compatment upper have been added.

• Various storage spaces have been added.
INTERIOR TRIM STRUCTURAL VIEW

dcf09175500Ot02
GLOVE COMPARTMENT UPPER
CUP HOLDER
CUP HOLDER
DOOR POCKET
(EXCEPT REGULAR CAB)
DCG917ZTBOOO
09-17-1
LIGHTING SYSTEMS
09-18 LIGHTING SYSTEMS

LIGHTING SYSTEM OUTLINE ........ 09-18-1 FRONT COMBINATION LIGHT
LIGHTING SYSTEMS CONSTRUCTION . ................ . 09-18-3
SPECiFiCATION .................. 09-18-1 REAR COMBINATION LIGHT
LIGHTING SYSTEM STRUCTURAL STRUCTURAL VIEW . ............. . 09-18-4
VIEW . .......................... 09-18-2
LIGHTING SYSTEM OUTLINE

dcf09180000Ot01
• Headlight with built-in front turn and parking light has been adopted.
• A projector type has been adopted to the headlight (low-beam).
• Stepped reflectors have been adopted to the rear combination lights.
LIGHTING SYSTEMS SPECIFICATION

dcf09180000Ot03
Item Specifications (W) x number
Headlight bulb
IHigh-beam 60 x 2
ILow-beam 55 x 2
Front turn light bulb 21 x 2
Parking light bulb 5x2
Front fog light bulb 55 x 2
Exterior light bulb capacity Front side turn light bulb 5x2
Brake/taillight bulb 21/5 x 2
Rear turn light bulb 21 x 2
Back-up light bulb 21 x 2
License plate light bulb 5x2
High-mount brake light bulb 5x4
Map light bulb 5x2
Interior light bulb 8x1
Interior light bulb capacity Glove compartment light bulb 1.7 x 1
IG key illumination bulb 1.4 x 1
Console illumination bulb 1.4 x 1
09-18-1
LIGHTING SYSTEMS
LIGHTING SYSTEM STRUCTURAL VIEW
dcf09180000Dt02
DCG918ZTBOOO
1 Front combination light Rear combination light

2 Front side turn light High-mount brake light
3 License plate light
09-18-2
LIGHTING SYSTEMS
DCG918ZTB001
1 Interior light (regular cab) Glove compartment light

2 Interior light (except regular cab) Console illumination
3 IG key illumination
FRONT COMBINATION LIGHT CONSTRUCTION

dcf091851060to1
• Projector type headlights (low-beam) have been adopted, and these have been incorporated, along with the
front turn light and the parking light, into a single unit to improve size reduction.
FRONT TURN
LIGHT BULB
HEADLIGHT
BULB
SEC.A-A SEC.B-B
09-18-3
LIGHTING SYSTEMS
REAR COMBINATION LIGHT STRUCTURAL VIEW
dcf09185115Ot03
TYPE A BRAKE
rrAILLIGHT BULB i.·
TURN LIGHT
BULB
BACK-UP
LIGHT BULB
REAR COMBINATION LIGHT TYPEB BACK-UP LIGHT
~
BRAKE rrAILLIGHT
TURN LIGHT SEC.A-A
'III'· II"
I I ,I
DCG918ZTB003
09-18-4
ENTERTAINMENT
09-20 ENTERTAINMENT
AUDIO SYSTEM OUTLINE . .......... 09-20-1 AUTO LEVEL CONTROL (ALC)
AUDIO SYSTEM STRUCTURAL FUNCTION . ..................... . 09-20-5
VIEW . .......................... 09-20-1 AUTO LEVEL CONTROL (ALC)
AUDIO SYSTEM BLOCK DIAGRAM ... 09-20-2 OPERATION . .................... . 09-20-5
AUDIO SYSTEM SPECIFICATIONS . ... 09-20-2 ON-BOARD DIAGNOSTIC SYSTEM
CENTER PANEL UNIT OUTLINE . ..... 09-20-3 OUTLINE . ...................... . 09-20-6
CENTER PANEL UNIT ON-BOARD DIAGNOSTIC SYSTEM
CONSTRUCTION ................. 09-20-3 FUNCTION . ..................... . 09-20-6
AUDIO UNIT STRUCTURAL VIEW . ... . 09-20-9
AUDIO UNIT CONSTRUCTION . ...... . 09-20-9
AUDIO SYSTEM OUTLINE

dcf092000001t01
Type A
• A center panel unit, composed of the installed audio unit and the audio switches built into the center panel, has
been adopted.
• Module availability depends on vehicle grade.
• The auto level control (ALC) function has been adopted.
Type B
• AM/FM radio with the CD player has been adopted.
AUDIO SYSTEM STRUCTURAL VIEW

dcf092000001t02
TWEETER RH
ANTENNA FEEDER
DCF920ZTBA02
09-20-1
ENTERTAINMENT
AUDIO SYSTEM BLOCK DIAGRAM
dcf092000001t03
TYPE A
ROOF
ANTENNA AUDIO
UNIT
CENTER PANEL /
UNIT ~ •• ---1-'::::=L==':'~
TWEETER
.1 I' (RH)
I'.1 FRONT SPEAKER

(RH)
FRONT SPEAKER
I'
(LH)
BASE UNIT
---4
TWEETER
.1 (LH)
-----n
REAR SPEAKER
(RH)
TNS SIGNAL
I~------ ... .
REAR SPEAKER
VEHICLE (LH)
SPEED
SIGNAL • .....L.___
___ 'I
II '*~~~E I i I
L.---.:.==~
TYPES
ROOF
ANTENNA
TWEETER
(RH)
FRONT SPEAKER
(RH)
FRONT SPEAKER
(LH)
AUDIO UNIT
TWEETER
(LH)
REAR SPEAKER
(RH)
REAR SPEAKER
(LH)
DCF920ZTBA03
09-20-2
ENTERTAINMENT
AUDIO SYSTEM SPECIFICATIONS

id092000100400
Audio Unit
Specification
Item Type A I Type 8
With RDS Without RDS l
Rated voltage (V) 12
LW (kHz) 153-279 -
Frequency band
FM
AM
MW (kHz)
(MHz)
531-1602
522-16291
530-1620
87.5-108
1 531-1629
Audio amplifier maximum output

(W) 35x4
power
Output impedance (ohm) 4
Speaker
Specification
Item
Front speaker I Rear speaker 1 Tweeter
I Double cab I Freestyle cab I
Maximum input (W) 25
Impedance (ohm) 4
Size (mm) 160 I 100 I 160 I 30
CENTER PANEL UNIT OUTLINE

dcf092066900to1
• The center panel unit is composed of the installed audio unit and the audio switches built into the center panel.
CENTER PANEL UNIT CONSTRUCTION

dcf09206690Ot02
Structural View
BASE UNIT
CENTER PANEL
AUDIO UNIT
b
COVER
LOWER MODULE
DCF920ZTBA01
09-20-3
ENTERTAINMENT
Terminal Layout and Signal
Audio unit
Terminal Signal
1A Front speaker LH (+) i'
1B B+ (Power back up)
1C Front speaker LH (-)
10 Front speaker RH (+)
1E TNS (+)
1F Front speaker RH (-)
1G Illumination (-)
1H Antenna control
11 Vehicle speed signal
1J
1K UART-1
1L
1M UART-2
1N
10
1P
10
1R ACC
1S Rear speaker LH (+)
1T
1U Rear speaker LH (-)
1V Rear speaker RH (+)
1W Power ground
1X Rear speaker RH (-)
Terminal Signal
2A Power ground
2B System mute
2C Input signal RH (+)
2D Input signal RH (-)
2E Input signal LH (+)
2F Input signal LH (-)
1m In! 2G Signal ground
2H TEXT DATA
20 2MI2KI21 12GI2EI2C 2A
2P 2NI2LI2J 12HI2FI2D 2B 21 TEXTCLK
2J TNS (+)
......... "" "'7
2K BUS (-)
2L BUS (+)
2M AUX control
2N -
20 ACC
2P +B
09-20-4
ENTERTAINMENT
Button and switch Location
~ I
I ®
C: 1
1/
@ II ® ® ®
I ,I
0
® @
1
I @) ,I (j])
1
I (jJ)
I
1
@
1
19
DCF920ZTBS03
1 CLOCK button 11 Preset button 3

2 LOAD button 12 Preset button 4
3 FM 1 button 13 Preset button 5
5 AM button 15 DISP/AUTO-M button
6 CD button 16 SEEKlAPCITRACK switch
7 MEDIA button 17 Traffic information button
8 EJECT button 18 AUDIO CONTITUNEITEXT button
9 Preset button 1 19 POWERNOLUME button
10 Preset button 2
AUTO LEVEL CONTROL (ALC) FUNCTION

dcf09206690Qt03
• Adjusts the audio volume so that the sound is balanced against wind and road noise while driving.
AUTO LEVEL CONTROL (ALC) OPERATION
dcf09206690Qt04
• The audio unit changes the volume automatically based on the vehicle speed signal sent from the instrument
cluster.
HIGHER VEHICLE SPEED
AUDIO UNIT (BASE UNIT)
SPEAKE R
VEHICLE SPEED SIGNAL ~ ALC

CIRCUIT
r- POWER
AMPLIFIER ~ HIGHER VOLUME
LOWER VEHICLE SPEED

AUDIO UNIT (BASE UNIT)
SPEAKE R
ALC
VEHICLE SPEED SIGNAL ~ CIRCUIT
,--
POWER
AMPLIFIER
- - -......~ NORMAL VOLUME
DCF920ZTBA04
09-20-5
ENTERTAINMENT
• The ALC function is divided into four modes that can be used effectively to match the driving conditions.
Mode Condition
RLC OFF ALC function cancelled
RLC LEUELl Outside road noise low
RLC LEUEL2 Outside road noise slightly high
RLC LEUEL3 Outside road noise high
ON-BOARD DIAGNOSTIC SYSTEM OUTLINE

dcf09206690Dt05
• The on-board diagnostic system has a self-diagnostic function and diagnostic assist function to help
technicians locate malfunctions.
ON-BOARD DIAGNOSTIC SYSTEM FUNCTION

dcf09206690Dt06
Self-diagnostic Function
Malfunction detection function
• The malfunction detection section detects malfunctions occurring in the system.
Memory function
• The memory function detects a malfunction, changes it to a DTC, and stores it in the memory. The memory can
store a maximum of three DTCs. If another malfunction is detected when three DTCs are already stored, the
memory function clears the oldest DTC and stores the new one.
• Once a DTC is stored, it can only be cleared by the designated procedure; not by turning the ignition switch to
the LOCK position or disconnecting the negative battery cable. The procedure is mentioned in the Service
Section.
Display function
• When the self-diagnostic function is activated, the information display displays the DTC stored in the memory.
• The DTC consists of the following codes and numbers:
- Supplier code (indicates manufacturer)
- Part number (indicates malfunctioning part)
- Error code (indicates malfunction description)
• Refer to the Service Section for the display method.
Supplier code Supplier name
1 SANYO Automedia
2 Panasonic SUPPLIER CODE
3 Clarion \ ERROR CODE
\
.--'.'-' '-'
4 Pioneer
1
·.-··.-·.-·,........2 07:Er011
Parts number Parts name ~
PART NUMBER
03 CD player
05 CD changer (external)
06 CD changer (upper module)
DCF920ZTBA09
07 MD player (lower module)
09 Base unit
10 MP3 applicable CD player
21 Center panel
22 MP3 applicable CD changer
Error code Malfunction description

01 Internal mechanism error
02 Servo mechanism error
07 Disc reading error
08 Blank media
09-20-6
ENTERTAINMENT
Error code Malfunction description

09 Unplayable files or tracks
10 BUS line (communication line) error
17 Incorrect combination
18 Incorrect combination
19 Communication line
20 Insufficient power supply
21 Amplifier related circuit
22 Tuner error
Screen display
Malfunction location
DTC Output signal
03: Er01 - CD player system
03: Er02 CHECK CD CD player system
03: Er07 CHECK CD CD player system
03: Er10 - CD player communication circuit system
05: Er01 - CD changer system
05: Er07 CHECK CD CD changer system
05: Er10 - CD changer communication circuit system
06: Er01 - CD changer system
06: Er10 - CD changer communication circuit system
07: Er01 - MD player system
07: Er02 CHECKMD MD player system
07: Er07 CHECKMD MD player system
07: Er08 - MD system
07: Er10 - MD player communication circuit system
09: Er20 - Power supply circuit to base unit
09: Er21 - Base unit (peripheral circuit for power amplifier)
09: Er22 - Base unit (peripheral circuit for tuner)
10: Er01 - MP3 applicable CD player system
10: Er02 CHECK CD MP3 applicable CD player system
10: Er07 CHECK CD MP3 applicable CD player system
10: Er09 CHECK CD MP3 applicable CD data
10: Er10 - MP3 applicable CD player communication circuit system
21: Er17 - Center panel system
22: Er01 - CD system
22: Er09 CHECK CD MP3 applicable CD data
22: Er10 - MP3 applicable CD changer system
no Er.r - No DTCs stored
Diagnostic Assist Function

• The diagnostic assist function displays the operating condition of the following functions (components) and
forces them to operate in order to examine whether they are malfunctioning or not.
• For the start procedure of each mode, refer to the Service Section.
09-20-7
ENTERTAINMENT
Information display
• The diagnostic assist function illuminates all
characters in the information display to check for
truncated or faint characters.
,-, '_1_ ,-1 ,-1 I

,-; ,-; _,-;
STCI:lI(J)@(i)@@@134
,-; MD IN
6.11"IRIPTIAUTOI·MIRDMIAFIPTY'ITAITPII
"
..... .....
___, _, CD IN 1 c
DCF902ZWBS04
Speaker
• The diagnostic assist function outputs sound to the speakers in the following order to determine the operating
condition of the speakers and wiring harnesses between the base unit and each speaker.
1. Front speaker and tweeter (LH)
2. Front speaker and tweeter (RH)
3. Rear speaker*1 (LH)
4. Rear speaker*1 (RH)
*1 : Mayor may not be equipped, depending on the vehicle.
Radio
• The diagnostic assist function displays the radio
reception condition in 10 levels (0-9) to assist in
determining the condition of the antenna, antenna
feeders, and base unit (tuner).
?
S-METER I
""""-'"'
0-9
E5U920ZS5008
Antenna control condition

• The diagnostic assist function displays the output
ANTENNA AMPLIFIER POWER SUPPLY IS OUTPUT
state of the antenna amplifier power supply to
determine the condition of the antenna amplifier,
base unit, and wiring harness between the base
unit and antenna amplifier. I=INT-ON
ANTENNA AMPLIFIER POWER SUPPLY IS NOT OUTPUT
I=INT-OFF E5U920ZS5202
09-20-8
ENTERTAINMENT
AUDIO UNIT STRUCTURAL VIEW dcf092066900to7
CBF920ZW4001
AUDIO UNIT CONSTRUCTION dcf092066900to8

Terminal Layout and Signals
AM/FM radio with CD player
Terminal Signal
1A Input RH (+)
1B Signal ground
1C Input LH (+)
10 Combi cont
1E -
101M 1K 11 1G1E 1C 1A 1F Aux cont
~~
1G Bus ground
1H Bus line
11 ACC
~jJ j2J!iJq Gl GCl 1J Power ground
1P 1~ ~i ~J fHfF ~o 1B 1K B+ (power back up)
1L System mute (input)
1M TNS (+)
1N Illumination (-)
10 -
1P -
2A ACC
2B -
2C B+ (power back up)
2M 2K 2E 2C 2A 2D -
2E TNS (+)
/~FlI~ 11 2F -
1'-------1
2H -
~= 2J -
2N 2L 2J 2H 2F 20 '2B 2K Front speaker LH (+)
2L Front speaker LH (-)
2M Front speaker RH (+)
2N Front speaker RH (-)
"
3A Rear speaker LH (+)
31 3C 3A 3B Rear speaker LH (-)
3C
~
-
3D -
3F Rear speaker RH (+)
Q.Q~ 3H Rear speaker RH (-)
3J 3H 3F 3D '3B 31 -
3J -
B 4A Ground (power)
09-20-9
POWER SYSTEMS
09-21 POWER SYSTEMS

POWER SYSTEMS STRUCTURA
VIEW •......•............•...... 09-21-1
POWER SYSTEMS STRUCTURAL VIEW

dcf092167730t02
DCF921ZTBOOl
09-21-1
INSTRUMENTATION/DRIVER INFO.
09-22 INSTRUMENTATION/DRIVER INFO.

INSTRUMENT CLUSTER OUTLINE .... 09-22-1 KEY REMINDER WARNING
INSTRUMENT CLUSTER ALARM CONSTRUCTION/
SPECiFiCATIONS ................. 09-22-1 OPERATION . .................... . 09-22-7
INSTRUMENT CLUSTER SPEEDOMETER CONTROL
STRUCTURAL ViEW .............. 09-22-2 OUTLINE ........................ 09-22-7
INSTRUMENT CLUSTER SPEEDOMETER CONTROL
SYSTEM WIRING DIAGRAM . ....... 09-22-3 CONSTRUCTION/OPERATION . ..... . 09-22-7
INPUT/OUTPUT CHECK MODE TACHOMETER CONTROL OUTLINE .. . 09-22-8
OUTLINE . ....................... 09-22-5 TACHOMETER CONTROL
INPUT/OUTPUT CHECK MODE CONSTRUCTION/OPERATION . ..... . 09-22-8
OPERATION ..................... 09-22-5 FUEL GAUGE CONTROL OUTLINE . .. . 09-22-8
LIGHTS-ON REMINDER WARNING FUEL GAUGE CONTROL
ALARM OUTLINE . ................ 09-22-6 CONSTRUCTION/OPERATION . ..... . 09-22-8
LIGHTS-ON REMINDER WARNING WATER TEMPERATURE GAUGE
ALARM CONSTRUCTION/ CONTROL OUTLINE . ............. . 09-22-9
OPERATION ..................... 09-22-6 WATER TEMPERATURE GAUGE
KEY REMINDER WARNING ALARM CONTROL CONSTRUCTION/
OUTLINE . ....................... 09-22-7 OPERATION . .................... . 09-22-9
HORN CONSTRUCTION ............ . 09-22-9
INSTRUMENT CLUSTER OUTLINE

dcf09225543Ot01
• LEDs have been adopted for warning and indicator lights installed on the instrument cluster.
• A flat-type horn has been adopted.
INSTRUMENT CLUSTER SPECIFICATIONS dcf092255430t02

Instrument Cluster
Item Specification
Meter type Stepping motor type
Indication range (km/h) 0-180
Speedometer
Input signal source Speedometer sensor
Rated voltage (V) DC12
Indication range (rpm) 0-5,000
(rpm) 4,500-5,000 (WL-3, WL-C)
Tachometer Red zone
4,250-5,000(WE-C)
Input signal source PCM
Meter type Stepping motor type (Reset-to-zero type)
Fuel gauge Input signal source Fuel gauge sender unit
Water (Medium range stabilized type)
temperature Input signal source Water temperature sender unit (WL-3)
gauge ECT sensor (WL-C, WE-C)
Display LCD
Odometer/
Indication digits Odometer: 6 digits, Tripmeter: 4 digits
Tripmeter
Warning Sound frequency (Hz) 2,000-2,200
alarms Output sound pressure level (dB) 67.5
Clock
Item Specification
Clock accuracy (Reference value)' (s/day) -1.5-1.5
, : If the clock accuracy varies largely from the reference value, battery deterioration or an audio unit (base unit)
malfunction may have occurred.
09-22-1
INSTRUMENT CLUSTER STRUCTURAL VIEW
id092200101200
Meter And Gauge
TACHOMETER SPEEDOMETER WATER TEMPERATURE GAUGE
ODOMETEMRIPMETER TRIPMETER SWITCH FUEL GAUGE

arnffn00000036
Warning And Indicator Light
arnffn00000420
09-22-2
No. Warning and indicator light Input signal source Note

1 RFW indicator light RFW control module 4x4
2 4x4 indicator light RFW main switch 4x4
3 Turn indicator light Flasher control module -
4 High-beam indicator light Headlight (HI) -
5 Fuel-level warning light Fuel gauge sender unit -
• ABS HU/CM (with 4-W ABS)
6 ABS warning light With ASS
• ABS control module (with rear ABS)
• Parking brake switch
7 Brake system warning light • Brake fluid level sensor -
• ABS HU/CM (with 4-W ABS)
• ABS control module (with rear ABS)
8 Air bag system warning light SAS control module With air bag system
9 Generator warning light Generator -
10 Security light • Immobilizer unit -
• Theft deterrent control module
11 Oil pressure warning light Oil pressure,switch -
12 Door ajar warning light Door switches -
13 Sedimentor warning light Sediment switch WE-C, WL-3, WL-C, WLT-1, WLT-2
14 MIL PCM -
15 Glow indicator light PCM WE-C, WL-3, WL-C, WLT-1, WLT-2
16 Front fog indicator light Front fog light relay With front fog light
17 Rear fog indicator light Rear fog light relay -
18 Seat belt warning light Buckle switch -
19 Selector indicator light TCM AT
20 OlD OFF indicator light TCM AT
09-22-2a
INSTRUMENT CLUSTER SYSTEM WIRING DIAGRAM
id092200101300
WATER TEMPERATURE GAUGE TACHOMETER

~E~GAUGE~PEEDOMETER
FUEL GAUGE SENDER UNIT
I
rr.=;i;l
;: : :
~
~I-----;
~ ~ ~~
n i.-- ODOMETERITRIPMETER
TRIPMETER SWITCH
~__________~~'~-41~-; r-~~i.--
I'--_-H-'"\.,.l'-I+_ _ --{~}---V----i ~
b ~
SPEEDOMETER SENSOR ~}----------------------~~
b ~1
VEHICLE SPEED
SIGNAL OUTPUT
'2Fl---"\.,
~ t MICRO-
COMPUTER r
~}-----------------------'
KEY REMINDER SWITCH ~
~~--{----{~r---E-N-G-IN-E-K-E-Y-~IL~L-U-M-IN-~-J-IO-N--~~
IPANEL LIGHT '2i3
ICONTROL SWITCH I ~'l-------I
Iv b ~
I PCM '2s:l-----I r-~-~~r---------,
~
riTi'i'\l ~
~}---------i r- fo,J------+----,
¥ b.
WATER TEMPERATURE SENDER UNIT
*~
OR ECT SENSOR r-- ~
~r_--~-H-~~r----------r;-~-,
-VI;K J
1 '-'
I~ST;UMENT
CLUSTER
ILLUMINATION
*
FUEL-LEVEL
DOOR SWITCH I ~WAR~G LIGHT
(DRIVER-SIDE) I ~ ~
DOOR SWITCH / DOOR AJAR
LIGHT
l6
(PASSENG~R-SIDE) I.e- WARNI~G LIGHT ~+ TNSRELAY
SWITCH
~. ~OOR S~'TCH (L~ ~1l--+!--l<I---O<&-'1,,->,\fv-----tt-=- ,j;' oo'~-------q+-t-t-----rm'"

~
c::.::rt-o-..-o--J1
DOOR SWITCH (RR)
~~~~~~r---r--ir. }-J
SECURJ6,Y LIGHT !;.+
~,}---+------(,...,,~tr------tt--"
klMMOBILIZER UNIT
~"O-Vt-r-{(~HE)}A'-'DLIGHT
THEFT-DETERRENT
I CONTROL MODULE
(;\
GENERATOR L :rgl--t1rt<J----4>---~~.Wv-----i
. - - - ....................... -
I 'r,-
.............. - - - - .. - - ...... - - - --I
GENERATOR
WARNING LIGHT
HEADLIGHT
RELAY
, : -------,0;---------.
p ~ --- --;~~f!~~~~~Ij
: SEDIME~WITCH , h : .~, '
. . o_ilf_T-N-S- '~
: ' 1G 'SEDIMENTOR:
l~_________________ <ai}--_ _ _ _-+-__ ---1_l+~

wr;-c, Wl.-S, Wl.-C. REAR FOG P .tn;{, I F~ FOG
WLT-1, WLT-2 INDICATOR LIGHT 8+ !.Jr FRONT LIGHT RELAY
~ ,--_...,-_~IDI.'tr-----'-'T FOG
..... I ~ LIGHT ,.., ~
~----~r-~ky~--------_1--------~~~
r-" ~ IJJ
HIGH-BEAM 1.Jr REAR R~ FOG
r--__IN_D_IC_~_JtI<t5.'0:9JRWiL,-IG--HT--+____{~iI_----------' FOG LIGHT RELAY
TURN INDICATOR I'-" LIGHT
~_L_IG_H_T~(L~~H~)\fv-_--I_-;~'~____________~-f---~~8~+--1
TURN INDICATOR P TURN L~HT (LH) I FLASHER
~_L_IG_H_T_(...,R,Q(~H~)\fv----I--;~. ~ ~ ~g~1~~L
....,. a P TURN ~HT (RH) J
_----
.........
-------......... .Jr ~
arnffn00000062
09-22-3
r---.-___-
a
---
RFW CONTROL II--___(~}---;R~F-W-IN-D-I-C_ij<
IDIATqrOWR\r-L_IG_H_T_.
IMODULE R I "-"
RFW MA.!!i§.WITCH 4X4 INDICATOR LIGHT

r----+I--~
~~1_ _ _--(~~-~---IDI~Mr--_.
...
,j,. rv " '0'
-WLT-1, WLT-2
-WL-C, WE-C
-WL-3 (WITH
ABS HU/CM (WITH 4W-ABS)
4W-ABS) or ABS I--"'-_(~J-t---';"'----t------------...J-Wi--r--------+-:_+
CONTROL MODULE P : :h :
(WITH REAR ABS) l_t' _____________ j
ABSWARNING
---------------.
,
~
' LI~T
:I. ,b. :
______________ ...
I . ______ _
---,!<,7------i-;,
WITHOUTABS
-----------~---------~
(WL-C, WE-C, WLT-1, WLT-2)
WITHOUT 4W-ABS (WL-3)
BRAKE FLUID
LEVEL SENSOR
r---{/r=/r--~_+:-----------{-~}_~--'~--~IDIMr--_.
l -WLT-1':WLT-2 :- -::------- ~
-WL-C, WE-C :
-WL-3 (WITH :
:
:
'BRAKESYSTEM
WARNING LIGHT
4W-ABS) ::
r-_--;~~~__'~-J_ ___1~r---~
,j,. ~R~NG ~
BRAKE SWITCH
r----;~~~-----_{~~~---~~~M---_+
"J,.. BUCKLE SWITCH i'--' SEAT BELT
WARNING LIGHT
WITH AIR
BAG SYSTEM
1-----------------
!ISASCONTROLI~:~--_(~r---t-------~----~
!IMODULE p ,- -, ~ :1.:
:- - - - - - - - - - - - - - - - J!! ~ AIR BAG~YSTEM
WITHOUT AIR!. ! WARNING LIGHT
BAG SYSTEM ,___ J
OIL PRESSURE
OIL PRESS~ SWITCH r- WARNINX LIGHT
~ ~r----------~'O'~----~
i--------l------t'1l ~ WE-C, WL-3, WL-C,

-.;.;.. ,---------------.:':"------------ V/ WLT-1, WLT-2
PCM
L...-_ _ _ _
'1A: GLOW INDIC~OR LIGHT
J---l"" :________________"::: __________ J
V
arnffn00000063
09-22-4
INSTRUMENT CLUSTER SYSTEM WIRING DIAGRAM[5R55S]
id0922001013z3
WATER TEMPER~ GAUGE TACHOMETER

FUEL GAUGE "/ ~PEEDOMETER
~~~~
n
FUEL GAUGE~DER UNIT
n
I-- ODOMETERfTRIPMETER
1 ~
9
~
J,.
~
@
- !---o~~ ,. I-- TRIPMETER SWITCH
I = ~
I~ g
I~'
If¥
~
~
~
~
TCM
kA
b 1~1
VEHICLE SPEED
~ MICRO- ~ ~
"2J KEY REMINDER SWITCH
SIGNAL OUTPUT
IPANEL LIGHT
~
t COMPUTER
n.
I'-'
~
ENGINE KEY,lkLUMINATION
~
CONTROL SWITCH I
~
F IV ~
.."
r-!
r bro
PCM L-s
I'-'
~
~
i=
~
.---- I-- I'-"
WATER TEMPERATURE SENDER UNIT
~
OR ECT SENSOR
t I;':;;
~ 1I
I'-'
I~ST;UMENT
CLUSTER
ILLUMINATION
FUEL-LEVEL
DOOR SWITCH
(DRIVER-SIDE)
It WARN~G LIGHT
DOOR SWITCH / DOOR AJAR

(PASSENG R-SIDE) LIGHT
kH WARNI~G LiGHT
"-"
~+ SWITCH ~RE~Y
~[~ '0"' ~
~
.",. , DOOR SWITCH (LR)

.",.
,l;"
U
A-
L.........J
J
DOOR SWITCH (RR)
1 B+
I IMMOBILIZER UNIT ~
SECURJJ,Y LIGHT
J-+ H~LlGHT (HIFW
I ~
p 0-
~
THEFT-DETERRENT
CONTROL MODULE kl...
iADLIGHT ( L ; \
1
I GENERATOR ~ p~ ~
HEADLIGHT
GENERATOR
,J;"' )-()..,2""""' RELAY
SEDIME~WITCH I WARNING LIGHT

to.
,J,.
'P1G SEDIMENTOR ,J;"' >-0...,.0
WARNING LIGHT
FRONT FOG
I .-:-::-01"
TNS
INDICATO~IGHT
"-"
-
-3 ;a,
11
I FRONT FOG
j.:
REAR FOG
INDICATO~..IGHT ~ I.h- FRONT LIGHT RELAY
FOG
~
I "-"
CV
LIGHT ~j:r
'-"
;a, J ~J J
HIGH-BEAM I.h- REAR REAR FOG
INDICAT,RR LIGHT
'fcl
'-"
FOG LIGHT RELAY
TURN INDICATOR LIGHT
LIGHT (LJciI
1M
~
TURN INDICATOR P TURN L~HT (LH)
I FLASHER
~ ± .."
LIGHT (RAil CONTROL
"-"
a p ~HT (RH) J MODULE
-----
TURN
, -, ,j,.
"'"
arnffn00000293
09-22-4a
-.------ a
--
4L INDICATOR LIGHT
~--~1F~--~----~~~~--~
\;,,;... 'U'
TCM
4X4 INDICATOR LIGHT
~----~1D'~--~-----4~~~--~
~ 'U'
ASS HU/CM (WITH

4W-ASS) or ASS t--....--{'2l~_-----1~--...J.t.~--~
CONTROL MODULE ~ ~
(WITH REAR ABS) ~ .
ABSWARNING
---------------.
,
~
' LI~T
: m-
1- ______________ ...
:
WITHOUTABS
(WL-C, WE-C, WLT-1, WLT-2)
BRAKE FLUID
LEVEL SENSOR
r---~~~----~----~1P~~--~--~~~~--~
1 '=--' \;,,;... BRAKESYSTEM
WARNING LIGHT
r----+v~~---4------~~.r---~
,.J,.. PARKING
BRAKE SWITCH
r----+v~~----------~1a.~~------~~~~--~
,.J,.. BUCKLE SWITCH ~ SEAT BELT
WARNING LIGHT
OlD OFF
"-"
OlD OFF INDICATOR LIGHT
TCM
WITH AIR
BAG SYSTEM
1-----------------
ilsASCONTROL~:~--;~r_--~------~r_--~
il MODULE
:________________ J
: ,- -,
i i
p *-
~ . AIR BAGq,YSTEM
WITHOUT AIRi" i WARNING LIGHT
BAG SYSTEM ,___ J
OIL PRESSURE
OIL PRESS~ SWITCH b WARNINQ LIGHT
~ ~r---------~~~~--~
r---------LI__~~r_--~----~~~IL~----_i
~ "-"
PCM
1_ GLOW INDIC,IlTOR LIGHT
'--______ ~
r----~A,r_--~------~r~Wr--~
p 'U'
"-"
--
SELECTOR INDICATOR LIGHT
arnffn00000294
09-22-4b
INPUT/OUTPUT CHECK MODE OUTLINE
dcf092255430t05
• The microcomputer built into instrument cluster detects the quality of input signals and individual parts.
• Input/output check mode has both input circuit inspection and individual part inspection functions.
I.
INPUT/OUTPUT CHECK MODE OPERATION
dcf09225543Ot06
Operation procedure
• Refer to Workshop Manual.
Input circuit check

• When the parts listed in the chart are operated and a signal is output to the instrument cluster, the built-in
microcomputer determines the operability of the input circuit based on that signal.
Check
Parts sending input signal
code
04 Door switch
08 TNS relay
10 Vehicle speed signal
11 Engine speed signal
22 Fuel gauge sender unit
24 • ECT sensor
• Water temperature sender unit
31 Key reminder switch
TNS SPEEDOMETER FUEL GAUGE ECT SENSOR OR KEY REMINDER

DOOR
RELAY SENSOR PCM SENDER UNIT WATER SWITCH
SWITCH
TEMPERATURE
~ ~ ~ } SENDER UNIT
~
II
LCD
INSTRUMENT
CLUSTER IMICROCOMPUTER I~~ ~
~
DCF922ZTB005
09-22-5
Individual circuit check
• By operating the parts listed in the chart, the built-in microcomputer determines the operability of the individual
parts.
Check
~ code
Parts sending input signal
12 Speedometer
13 Tachometer
14 Buzzer
16 Fuel-level warning light
18 Engine key illumination output
23 Fuel gauge
25 Water temperature gauge
26 LCD, warning and indicator light
WATER
SP(;TERG) TACHOMETER
BUZZER
LCD,
WARNING AND
INDICATOR LIGHT
TEMPERATURE
GAUGE
ENGINE KEY
ILLUMINATION
c~
MICROCOMPUTER
INSTRUMENT CLUSTER
DCF922ZTB006
LIGHTS-ON REMINDER WARNING ALARM OUTLINE

dcf09225543Ot07
• Warns the driver that the headlights or TNS are on when the driver-side door is opened.
LIGHTS-ON REMINDER WARNING ALARM CONSTRUCTION/OPERATION

dcf092255430t08
System Wiring Diagram

B+
B+
TO LIGHT INSTRUMENT
SWITCH CLUSTER
MICROCOMPUTER
BUZZER
DOOR SWITCH
(DRIVER-SIDE)
DCF922ZTB007
Operation
• The buzzer in the instrument cluster sounds continuously when all the following three conditions are met:
The engine switch is in the LOCK or ACC position.
- The headlight switch is in the TNS or headlight position.
- The driver-side door is open (driver-side door switch is on).
09-22-6
KEY REMINDER WARNING ALARM OUTLINE
dcf09225543Ot11
• Warns the driver that the key is in the steering lock when the driver-side door is opened.
,r
KEY REMINDER WARNING ALARM CONSTRUCTION/OPERATION
dcf09225543Ot1 ~\ .
B+KEY REMINDER IG1

B+
~TCH
INSTRUMENT CLUSTER
BUZZER
DOOR SWITCH
(DRIVER-SIDE)
DCF922ZTB008
Operation
• The buzzer in the instrument cluster sounds when all the following three conditions are met:
The engine switch is in the LOCK or ACC position.
- The key is in the steering lock (key reminder switch is on).
- The driver-side door is open (driver-side door switch is on).
SPEEDOMETER CONTROL OUTLINE i·

dcf09225543Ot15
• The vehicle speed signal is output from the speedometer sensor to the microcomputer in the instrument cluster.
SPEEDOMETER CONTROL CONSTRUCTION/OPERATION

dcf09225543Ot16
System Wiring Diagram-
IG1 B+
SPEEDOMETER
INSTRUMENT
CLUSTER
Operation
• The vehicle speed signal sent from the speedometer sensor is input to the microcomputer in the instrument
cluster. The microcomputer calculates the current vehicle speed based on the vehicle speed signal, and sends
an output signal to the speedometer.
09-22-7
TACHOMETER CONTROL OUTLINE
dcf09225543ot17
• The engine speed signal is output from the PCM to the microcomputer in the instrument cluster.
TACHOMETER CONTROL CONSTRUCTION/OPERATION

, dcf092255430t 18
IG1 B+
TACHOMETER
INSTRUMENT
CLUSTER
DCF922ZTB010
Operation
• The engine speed signal sent from the PCM is input to the microcomputer in the instrument cluster. The
microcomputer calculates the current engine speed based on the engine speed signal, and sends an output
signal to the tachometer.
FUEL GAUGE CONTROL OUTLINE

dcf092255430t 19
• The fuel level signal is output from the fuel gauge sender unit to the microcomputer in the instrument cluster.
Fuel gauge variation caused by fluctuating fuel level when cornering or driving on a slope, is reduced by
microcomputer control.
FUEL GAUGE CONTROL CONSTRUCTION/OPERATION

dcf09225543ot20

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

dcf09225543Ot22
IG1 B+
WATER TEMPERATURE GAUGE
INSTRUMENT
CLUSTER
WATER TEMPERATURE
SENDER UNIT OR ECT SENSOR
DCF922ZTB012
Operation
• The engine coolant temperature signal sent from the water temperature sender unit or ECT sensor is input to
the microcomputer in the instrument cluster. The microcomputer calculates the current engine coolant
temperature based on the engine coolant temperature signal, and sends an output signal to the water
temperature gauge.
HORN CONSTRUCTION
dcf09226679Ot01
• A flat-type horn has been adopted.
DCF922ZTB013
09-22-9
ALPHABETICAL INDEX
ACCELERATOR PEDAL POSITION
A (APP) SENSOR FUNCTION

[WL-C, WE-C] .......................... 01-40B-23
AIM OF DEVELOPMENT ..................... 00-00-1
AlC COMPRESSOR CONSTRUCTION ......... 07-11-4 AIR BAG SYSTEM OUTLINE. ................. 08-10-1
AlC CUT-OFF CONTROL AIR BAG SYSTEM STRUCTURAL VIEW ........ 08-10-2
BLOCK DIAGRAM [WL-3] ................. 01-40A-14 AIR BAG SYSTEM WIRING DIAGRAM .......... 08-10-2
AlC CUT-OFF CONTROL AIR CHARGING SYSTEM DIAGRAM
CONDITION [WL-3] ...................... 01-40A-14 [WL-C, WE-C] ........................... 01-13B-4
AlC CUT-OFF CONTROL OUTLINE [WL-3] .... 01-40A-14 AIR CHARGING SYSTEM OPERATION
AlC CUT-OFF CONTROL [WL-C, WE-C] ........................... 01-13B-4
BLOCK DIAGRAM [WL-C, WE-C] ........... 01-40B-18 AIR CHARGING SYSTEM OUTLINE
AlC CUT-OFF CONTROL [WL-C, WE-C] ........................... 01-13B-4
OPERATION [WL-C, WE-C] ............... 01-40B-18 AIR CLEANER CONSTRUCTION [WL-3] ....... 01-13A-3
AlC CUT-OFF CONTROL AIR CLEANER CONSTRUCTION
OUTLINE [WL-C, WE-C] .................. 01-40B-18 [WL-C, WE-C] ........................... 01-13B-3
ABS CM PART CONSTRUCTION/ AUDIO SYSTEM BLOCK DIAGRAM ............ 09-20-2
OPERATION [REAR ABS] ................. 04-13A-6 AUDIO SYSTEM OUTLINE ................... 09-20-1
ABS CM PART FUNCTION [4W-ABS] ......... 04-13B-5 AUDIO SYSTEM SPECIFICATIONS ............ 09-20-2
ABS CM PART FUNCTION [REAR ABS] ....... 04-13A-5 AUDIO SYSTEM STRUCTURAL VIEW .......... 09-20-1
ABS CONTROL OPERATION [REAR ABS] ..... 04-13A-8 AUDIO UNIT CONSTRUCTION ................ 09-20-9
ABS CONTROL OPERATION [4W-ABS] ....... 04-13B-6 AUDIO UNIT STRUCTURAL VIEW ............. 09-20-9
ABS CONTROL OUTLINE [4W-ABS] .......... 04-13B-5 AUTO LEVEL CONTROL (ALC) FUNCTION ...... 09-20-5
ABS CONTROL OUTLINE [REAR ABS] ........ 04-13A-7 AUTO LEVEL CONTROL (ALC)
ABS HU PART CONSTRUCTION/ OPERATION ............................. 09-20-5
OPERATION [4W-ABS] .................... 04-13B-3 AUTO TENSIONER CONSTRUCTION
ABS HU PART CONSTRUCTION/ [WL-C, WE-C] ........................... 01-10B-8
OPERATION [REAR ABS] ................. 04-13A-3
ABS HU PART FUNCTION [4W-ABS] .......... 04-13B-3
ABS HU PART FUNCTION [REAR ABS] ....... 04-13A-2 B
ABS HU/CM CONSTRUCTION [4W-ABS] ...... 04-13B-2
ABS OUTLINE [4W-ABS] ................... 04-13B-1 BASIC SYSTEM LOCATION INDEX ............ 07-11-1
ABS OUTLINE [REAR ABS] ................. 04-13A-1 BLOWER MOTOR CONSTRUCTION ........... 07-40-2
ABS SPEED SENSOR AND ABS BLOWER UNIT CONSTRUCTION/OPERATION .. 07-11-2
SENSOR ROTOR CONSTRUCTION/ BODY AND ACCESSORIES ABBREVIATIONS ... 09-00-1
OPERATION [REAR ABS] ................. 04-13A-9 BODY AND ACCESSORIES FEATURES ........ 09-00-1
ABS SPEED SENSOR FUNCTION BODY PANEL OUTLINE ..................... 09-10-1
[REAR ABS] ............................ 04-13A-8 BODY PANEL STRUCTURAL VIEW ............ 09-10-1
ABS STRUCTURAL VIEW [4W-ABS] .......... 04-13B-1 BOOST PRESSURE CONTROL
ABS STRUCTURAL VIEW [REAR ABS] ........ 04-13A-1 BLOCK DIAGRAM [WL-C, WE-C] ........... 01-40B-12
ABS SYSTEM WIRING DIAGRAM BOOST PRESSURE CONTROL
[4W-ABS] .............................. 04-13B-2 OPERATION [WL-C, WE-C] ............... 01-40B-12
ABS SYSTEM WIRING DIAGRAM BOOST PRESSURE CONTROL
[REAR ABS] ............................ 04-13A-2 OUTLINE [WL-C, WE-C] .................. 01-40B-12
ABS WHEEL-SPEED SENSOR AND BOOST SENSOR CONSTRUCTION/
ABS SENSOR ROTOR FUNCTION OPERATION [WL-3] ..................... 01-40A-17
[4W-ABS] ........................ , ...... 04-13B-6 BOOST SENSOR CONSTRUCTION/
ABS WHEEL-SPEED SENSOR AND OPERATION [WL-C, WE-C] ............... 01-40B-22
ABS SENSOR ROTOR BOOST SENSOR FUNCTION [WL-3] ......... 01-40A-17
CONSTRUCTION/OPERATION [4W-ABS] ..... 04-13B-6 BOOST SENSOR FUNCTION [WL-C, WE-C] ... 01-40B-22
ACCELERATOR PEDAL COMPONENT BRAKE ABBREVIATIONS .................... 04-00-1
CONSTRUCTION [WL-C, WE-C] ............ 01-13B-6 BRAKE FEATURES ......................... 04-00-1
ACCELERATOR PEDAL COMPONENT BRAKE SPECIFICATIONS ................... 04-00-2
DESCRIPTION [WL-3] .................... 01-13A-5
I c 11m
ACCELERATOR PEDAL POSITION
(APP) SENSOR CONSTRUCTION/
OPERETION [WL-3] ..................... 01-40A-18
ACCELERATOR PEDAL POSITION CAMSHAFT CONSTRUCTION [WL-3] ......... 01-10A-9
(APP) SENSOR DESCRIPTION CAMSHAFT CONSTRUCTION [WL-C, WE-C] ... 01-10B-8
[WL-C, WE-C] .......................... 01-40B-23 CAMSHAFT POSITION (CMP) SENSOR
ACCELERATOR PEDAL POSITION CONSTRUCTION/OPERATION
(APP) SENSOR FUNCTION [WL-3] ......... 01-40A-18 [WL-C, WE-C] .......................... 01-40B-26
AI-1
ALPHABETICAL INDEX
CAMSHAFT POSITION (CMP) SENSOR COOLING SYSTEM

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

CONDITIONS [WL-C, WE-C] ............... 01-02B-9 ENGINE CONTROL SYSTEM
DTC TABLE [WL-3] ........................ 01-02A-4 BLOCK DIAGRAM [WL-3] .................. 01-40A-7
DTC TEST MODE [WL-C, WE-C] ............. 01-02B-6 ENGINE CONTROL SYSTEM
DUAL-MASS FLYWHEEL FUNCTION BLOCK DIAGRAM [WL-C, WE-C] ............ 01-40B-9
[S15M-D, S15MX-D] ....................... 05-10-3 ENGINE CONTROL SYSTEM
DIAGRAM [WL-3] ......................... 01-40A-4
E Ii
DIAGRAM [WL-C, WE-C] ................... 01-40B-4
EGR CONTROL BLOCK DIAGRAM [WL-3] .... 01-40A-13 OUTLINE [WL-3] ......................... 01-40A-2
EGR CONTROL BLOCK ENGINE CONTROL SYSTEM
DIAGRAM [WL-C, WE-C] ................. 01-40B-17 OUTLINE [WL-C, WE-C] ................... 01-40B-2
EGR CONTROL OPERATION [WL-3] ......... 01-40A-13 ENGINE CONTROL SYSTEM
EGR CONTROL OPERATION [WL-C, WE-C] ... 01-40B-17 RELATION CHART [WL-3] ................. 01-40A-8
EGR CONTROL OUTLINE [WL-3] ., ......... 01-40A-13 ENGINE CONTROL SYSTEM
EGR CONTROL OUTLINE [WL-C, WE-C] ..... 01-40B-17 RELATION CHART [WL-C, WE-C] .......... 01-40B-10
EGR CONTROL SOLENOID VALVE ENGINE CONTROL SYSTEM
DESCRIPTION [WL-3] .................... 01-16A-5 STRUCTURAL VIEW [WL-3] ................ 01-40A-3
DESCRIPTION [WL-C, WE-C] .............. 01-16B-5 STRUCTURAL VIEW [WL-C, WE-C] .......... 01-40B-3
FUNCTION [WL-3] ....................... 01-16A-5 WIRING DIAGRAM [WL-3] ................. 01-40A-5
FUNCTION [WL-C, WE-C] ................. 01-16B-5 WIRING DIAGRAM [WL-C, WE-C] ........... 01-40B-5
EGR COOLER DESCRIPTION [WL-3] ......... 01-16A-6 ENGINE COOLANT TEMPERATURE
EGR COOLER DESCRIPTION [WL-C, WE-C] ... 01-16B-6 (ECT) SENSOR CONSTRUCTIONI
EGR COOLER FUNCTION [WL-3] ............ 01-16A-5 OPERATION [WL-3] ................ " ... 01-40A-22
EGR COOLER FUNCTION [WL-C, WE-C] ...... 01-16B-5 ENGINE COOLANT TEMPERATURE
EGR SORENOID VALVE (VACUUM, VENT) (ECT) SENSOR CONSTRUCTIONI
DESCRIPTION [WL-3] .................... 01-16A-5 OPERATION [WL-C, WE-C] ............... 01-40B-25
EGR SORENOID VALVE (VACUUM, VENT) ENGINE COOLANT TEMPERATURE
FUNCTION [WL-3] ....................... 01-16A-5 (ECT) SENSOR FUNCTION [WL-3] ......... 01-40A-22
EGR SORENOID VALVE ENGINE COOLANT TEMPERATURE
DESCRIPTION [WL-C, WE-C] .............. 01-16B-5 (ECT) SENSOR FUNCTION [WL-C, WE-C] ... 01-40B-25
EGR SORENOID VALVE ENGINE FEATURES [WL-3, WL-C, WE-C] ....... 01-00-2
FUNCTION [WL-C, WE-C] ................. 01-16B-5 ENGINE MOUNT STRUCTURAL VIEW
EGR SYSTEM DIAGRAM [WL-3] ............. 01-16A-4 [WL-3] ................................. 01-10A-10
EGR SYSTEM DIAGRAM [WL-C, WE-C] ....... 01-16B-4 ENGINE MOUNT STRUCTURAL
EGR SYSTEM FUNCTION [WL-3] ............ 01-16A-4 VIEW [WL-C, WE-C] ...................... 01-10B-9
EGR SYSTEM FUNCTION [WL-C, WE-C] ...... 01-16B-4 ENGINE SPECIFICATION [WL-3] .............. 01-00-3
EGR SYSTEM OPERATION [WL-3] ........... 01-16A-4 ENGINE SPECIFICATION [WL-C, WE-C] ........ 01-00-5
EGR SYSTEM OPERATION [WL-3] ........... 01-16A-5 ENGINE STRUCTURAL VIEW [WL-3] .... " .... 01-10A-1
EGR SYSTEM OPERATION [WL-C, WE-C] ..... 01-16B-4 ENGINE STRUCTURAL VIEW [WL-C, WE-C] .... 01-10B-1
EGR SYSTEM OPERATION [WL-C, WE-C] ..... 01-16B-5 EVAPORATIVE CHAMBER
EGR SYSTEM OUTLINE [WL-3] .............. 01-16A-4 CONSTRUCTION/OPERATIN [WL-3] ......... 01-16A-7
EGR SYSTEM OUTLINE [WL-C, WE-C] ........ 01-16B-4 EVAPORATIVE CHAMBER
EGR VALVE POSITION SENSOR FUNCTION [WL-3] ........................ 01-16A-7
FUNCTION [WL-3] ...................... 01-40A-23 EXHAUST SYSTEM OUTLINE [WL-3] .......... 01-15A-1
EGR VALVE POSITION SENSOR EXHAUST SYSTEM OUTLINE [WL-C, WE-C] ... 01-15B-1
FUNCTION [WL-C, WE-C] ................ 01-40B-27 EXHAUST SYSTEM STRUCTURAL
ELECTRONIC GOVERNOR VIEW [WL-3] ............................ 01-15A-1
CONSTRUCTION [WL-3] .................. 01-14A-7 EXHAUST SYSTEM STRUCTURAL
ELECTRONIC GOVERNOR VIEW [WL-C, WE-C] ...................... 01-15B-1
FUNCTION [WL-3] ....................... 01-14A-6 EXTERIOR TRIM OUTLINE ................... 09-16-1
ELECTRONIC GOVERNOR EXTERIOR TRIM STRUCTURAL VIEW ......... 09-16-1
FilII
OPERATION [WL-3] ...................... 01-14A-7
EMISSION SYSTEM DIAGRAM [WL-3] ........ 01-16A-3
EMISSION SYSTEM DIAGRAM [WL-C, WE-C] .. 01-16B-3 Ii
EMISSION SYSTEM OUTLINE [WL-3] ......... 01-16A-1
EMISSION SYSTEM OUTLINE [WL-C, WE-C] ... 01-16B-1 FAIL-SAFE FUNCTION [WL-3] ............... 01-02A-4 .
EMISSION SYSTEM STRUCTURAL FAILURE DETECTION FUNCTION [WL-3] ...... 01-02A-4
VIEW [WL-3] ............................ 01-16A-2 FAILURE INDICATION FUNCTION [WL-3] ...... 01-02A-4
EMISSION SYSTEM STRUCTURAL FRONT AXLE OUTLINE ..................... 03-11-1
VIEW [WL-C, WE-C] ...................... 01-16B-2 FRONT AXLE CROSS-SECTIONAL VIEW ....... 03-11-1
AI-3
ALPHABETICAL INDEX
FRONT BRAKE (DISC) CONSTRUCTION ....... 04-11-6 FUEL PRESSURE CONTROL

FRONT COMBINATION LIGHT OPERATION [WL-C, WE-C] ............... 01-40B-16
CONSTRUCTION .......................... 09-18-3 FUEL PRESSURE CONTROL
FRONT DRIVE SHAFT OUTLINE [WL-C, WE-C] .................. 01-40B-16
CROSS-SECTIONAL VI EW .................. 03-13-1 FUEL PRESSURE SENSOR
FRONT DRIVE SHAFT OUTLINE .............. 03-13-1 CONSTRUCTION/OPERATION
FRONT LOWER ARM AND TIE ROD [WL-C, WE-C] ......................... 01-40B-25
CONSTRUCTION [4x2 (EXCEPT Hi-Rider)] ..... 02-13-3 FUEL PRESSURE SENSOR
FRONT SUSPENSION DESCRIPTION .......... 02-13-3 FUNCTION [WL-C, WE-C] ................ 01-40B-24
FRONT SUSPENSION OUTLINE .............. 02-13-1 FUEL PUMP SPEED SENSOR
FRONT SUSPENSION STRUCTURAL ViEW ..... 02-13-1 CONSTRUCTION [WL-3] ................. 01-40A-20
FRONT WHEEL ALIGNMENT DESCRIPTION .... 02-11-1 FUEL PUMP SPEED SENSOR
FUEL CUT SOLENOID VALVE FUNCTION [WL-3] ...................... 01-40A-19
FUNCTION [WL-3] ........................01-14A-8 FUEL PUMP SPEED SENSOR
FUEL CUT SOLENOID VALVE OPERATION [WL-3] ..................... 01-40A-20
OPERATION [WL-3] ....................... 01-14A-8 FUEL SYSTEM DIAGRAM [WL-3] ............ 01-14A-3
FUEL FILTER CONSTRUCTION/ FUEL SYSTEM DIAGRAM [WL-C, WE-C] ...... 01-14B-3
OPERATION [WL-3] ....................... 01-14A-4 FUEL SYSTEM OUTLINE [WL-3] ............. 01-14A-1
FUEL FILTER CONSTRUCTION/ FUEL SYSTEM OUTLINE [WL-C, WE-C] ....... 01-14B-1
OPERATION [WL-C, WE-C] ................. 01-14B-5 FUEL SYSTEM STRUCTUAL VIEW [WL-3] ..... 01-14A-2
FUEL FILTER FUNCTION [WL-3] ............. 01-14A-4 FUEL SYSTEM STRUCTURAL VIEW
FUEL FILTER FUNCTION [WL-C, WE-C] ....... 01-14B-4 [WL-C, WE-C] ........................... 01-14B-2
FUEL GAUGE CONTROL OUTLINE ............ 09-22-8 FUEL TANK CONSTRUCTION [WL-C, WE-C] ... 01-14B-4
FUEL GAUGE CONTROL FUEL TANK CONSTRUCTION [WL-3] ......... 01-14A-4
CONSTRUCTION/OPERATION .............. 09-22-8 FUEL TEMPERATURE SENSOR .
FUEL INJECTION AMOUNT CONTROL CONSTRUCTION/OPERATION
BLOCK DIAGRAM [WL-C, WE-C] .......... .Q1~40B-13 [WL-C, WE-C] ......................... 01-40B-24
FUEL INJECTION AMOUNT FUEL TEMPERATURE SENSOR
CONTROL BLOCK DIAGRAM [WL-3] ........ 01-40A-10 CONSTRUCTION/OPERATION [WL-3] ...... 01-40A-19
FUEL INJECTION AMOUNT CONTROL FUEL TEMPERATURE SENSOR
OPERATION [WL-C, WE-C] ................01-40B-13 FUNCTION [WL-3] ...................... 01-40A-19
FUEL INJECTION AMOUNT FUEL TEMPERATURE SENSOR
CONTROL OUTLINE [WL-3] ...............01-40A-10 FUNCTION [WL-C, WE-C] ................ 01-40B-24
FUEL INJECTION AMOUNT CONTROL
OUTLINE [WL-C, WE-C] .................. 01-40B-12
FUEL INJECTION AMOUNT G
CONTROL OPERATION [WL-3] ............ 01-40A-11
FUEL INJECTION PUMP G SENSOR CONSTRUCTION/
CONSTRUCTION [WL-3] ................... 01-14A-5 OPERATION [4W-ABS] ................... 04-13B-7
FUEL INJECTION PUMP FUNCTION [WL-3] .... 01-14A-4 G SENSOR FUNCTION [4W-ABS] ............ 04-13B-7
FUEL INJECTION PUMP OPERATION [WL-3] ... 01-14A-5 GENERATOR CONSTRUCTION
FUEL INJECTION TIMING CONTROL [WL-3, WL-C, WE-C] .................... " 01-17-2
BLOCK DIAGRAM [WL-C, WE-C] ........... 01-40B-14 GLOW CONTROL BLOCK DIAGRAM [WL-3] ... 01-40A-9
FUEL INJECTION TIMING GLOW CONTROL
CONTROL OPERATION [WL-3] ............ 01-40A-12 BLOCK DIAGRAM [WL-C, WE-C] .......... 01-40B-11
FUEL INJECTION TIMING CONTROL GLOW CONTROL OPERATION
OPERATION [WL-C, WE-C] ................ 01-40B-14 [WL-C, WE-C] ......................... 01-40B-12
FUEL INJECTION TIMING GLOW CONTROL OPERATION [WL-3] ........ 01-40A-9
CONTROL OUTLINE [WL-3] ...............01-40A-12 GLOW CONTROL OUTLINE [WL-3]. .......... 01-40A-9
FUEL INJECTION TIMING CONTROL GLOW CONTROL OUTLINE [WL-C, WE-C] ... 01-40B-11
OUTLINE [WL-C, WE-C] .................. 01-40B-13 GLOW PLUG CONSTRUCTION [WL-3] ........ 01-13A-7
FUEL INJECTION TIMING CONTROL GLOW PLUG CONSTRUCTION [WL-C, WE-C] .. 01-13B-7
BLOCK DIAGRAM [WL-3] .................01-40A-12 GLOW PLUG FUNCTION [WL-3] ............. 01-13A-6
FUEL INJECTOR CONSTRUCTION GLOW PLUG FUNCTION [WL-C, WE-C] ....... 01-13B-6
[WL-C, WE-C] ...........................01-14B-10 GLOW PLUG OUTLINE [WL-3] " ............ 01-13A-6
FUEL INJECTOR FUNCTION [WL-C, WE-C] ... 01-14B-10 GLOW PLUG RELAY OPERATION [WL-3] ..... 01-13A-7
FUEL INJECTOR OPERATION [WL-C, WE-C] .. 01-14B-12 GLOW PLUG RELAY OPERATION
FUEL METERING VALVE [WL-C, WE-C] .......................... 01-13B-7
CONSTRUCTION/OPERATION GLOW SYSTEM CONSTRUCTION
[WL-C, WE-C] ...........................01-14B-9 [WL-C, WE-C] .......................... 01-13B-6
FUEL METERING VALVE GLOW SYSTEM OPERATION [WL-3] ......... 01-13A-5
FUNCTION [WL-C, WE-C] ..................01-14B-9 GLOW SYSTEM OPERATION [WL-C, WE-C] ... 01-13B-6
FUEL PRESSURE CONTROL GLOW SYSTEM OUTLINE [WL-3] ............ 01-13A-5
BLOCK DIAGRAM [WL-C, WE-C] ........... 01-40B-16 GLOW SYSTEM OUTLINE [WL-C, WE-C] ...... 01-13B-6
AI-4
ALPHABETICAL INDEX
H SENSOR NO.1 CONSTRUCTION/

OPERATION [WL-C, WE-C] ............... 01-40B-22
HORN CONSTRUCTION .................... 09-22-9 SENSOR NO.1 FUNCTION [WL-3] ......... 01-40A-16
HVAC ABBREVIATION ...................... 07-00-1 INTAKE AIR TEMPERATURE (IAT)
HVAC FEATURES .......................... 07-00-1 SENSOR NO.1 FUNCTION [WL-C, WE-C] .... 01-40B-21
HVAC SPECIFICATIONS .................... 07-00-1 INTAKE AIR TEMPERATURE (lAT)
SENSOR NO.2 CONSTRUCTION/
I OPERATION [WL-3] ..................... 01-40A-16
INTAKE AIR TEMPERATURE (lAT)
SENSOR NO.2 CONSTRUCTION/
IDLE SPEED CONTROL BLOCK OPERATION [WL-C, WE-C] ............... 01-40B-21
DIAGRAM [WL-C, WE-C] ................. 01-40B-11 INTAKE AIR TEMPERATURE (IAT)
IDLE SPEED CONTROL SENSOR NO.2 FUNCTION [WL-3] .......... 01-40A-15
OPERATION [WL-C, WE-C] ............... 01-40B-11 INTAKE AIR TEMPERATURE (IAT)
IDLE SPEED CONTROL OUTLINE SENSOR NO.2 FUNCTION [WL-C, WE-C] .... 01-40B-21
[WL-C, WE-C] .......................... 01-40B-10 INTAKE SHUTIER SOLENOID VALVE
IDLE SWITCH CONSTRUCTION/ DESCRIPTION [WL-C, WE-C] ............... 01-16B-6
OPERETION [WL-3] ..................... 01-40A-19 INTAKE SHUTIER VALVE
IDLE SWITCH DESCRIPTION DESCRIPTION [WL-C, WE-C] ............... 01-16B-6
[WL-C, WE-C] .......................... 01-40B-24 INTERIOR TRIM OUTLINE ................... 09-17-1
IDLE SWITCH FUNCTION [WL-3] ............ 01-40A-19 INTERIOR TRIM STRUCTURAL VIEW .......... 09-17-1
IDLE SWITCH FUNCTION [WL-C, WE-C] ..... 01-40B-23
IMMOBILIZER SYSTEM BLOCK
DIAGRAM [WL-C, WE-C] ................. 01-40B-19
IMMOBILIZER SYSTEM
K
OPERATION [WL-C, WE-C] ............... 01-40B-19 KEY REMINDER WARNING ALARM OUTLINE ... 09-22-7
IMMOBILIZER SYSTEM OPERATION ......... 09-14-10 KEY REMINDER WARNING
IMMOBILIZER SYSTEM ALARM CONSTRUCTION/OPERATION ........ 09-22-7
OUTLINE [WL-C, WE-C] .................. 01-40B-19 KEYLESS ENTRY SYSTEM OPERATION ....... 09-14-2
IMMOBILIZER SYSTEM OUTLINE ............. 09-14-7 KEYLESS ENTRY SYSTEM OUTLINE .......... 09-14-1
IMMOBILIZER SYSTEM STRUCTURAL VIEW ... 09-14-8 KEYLESS ENTRY SYSTEM
IMMOBILIZER SYSTEM SYSTEM STRUCTURAL VIEW ....................... 09-14-1
COMPONENT. : .......................... 09-14-9 KEYLESS ENTRY SYSTEM
IMMOBILIZER SYSTEM WIRING DIAGRAM ..... 09-14-8 WIRING DIAGRAM ........................ 09-14-2
INJECTION NOZZLE KOEO/KOER SELF-TEST [WL-3] ............. 01-02A-8
CONSTRUCTION/OPERATION [WL-3] ....... 01-14A-9 KOEO/KOER SELF-TEST [WL-C, WE-C] ...... 01-02B-16
INJECTION NOZZLE FUNCTION [WL-3] ....... 01-14A-9
INJECTION PUMP EPROM
CONSTRUCTION [WL-3] .................. 01-14A-9 L
INJECTION PUMP EPROM
FUNCTION [WL-3] ....................... 01-14A-9 LIGHTING SYSTEM OUTLINE ................ 09-18-1
INPUT/OUTPUT CHECK MODE OPERATION .... 09-22-5 LIGHTING SYSTEM STRUCTURAL VIEW ....... 09-18-2
INPUT/OUTPUT CHECK MODE OUTLINE ...... 09-22-5 LIGHTING SYSTEMS SPECIFICATION ......... 09-18-1
INSTRUMENT CLUSTER OUTLINE ............ 09-22-1 LIGHTS-ON REMINDER WARNING
INSTRUMENT CLUSTER SPECIFICATIONS ..... 09-22-1 ALARM CONSTRUCTION/OPERATION ........ 09-22-6
INSTRUMENT CLUSTER LIGHTS-ON REMINDER WARNING
STRUCTURAL VIEW ...................... 09-22-2 ALARM OUTLINE ......................... 09-22-6
INSTRUMENT CLUSTER LOAD LIMITER RETRACTOR
SYSTEM WIRING DIAGRAM ................ 09-22-3 CONSTRUCTION/OPERATION .............. 08-11-1
INTAKE AIR SYSTEM DIAGRAM [WL-3] ....... 01-13A-3 LOAD SENSING PROPORTIONING
INTAKE AIR SYSTEM DIAGRAM VALVE (LSPV) CONSTRUCTION ............. 04-11-3
[WL-C, WE-C] ........................... 01-13B-3 LOAD SENSING PROPORTIONING
INTAKE AIR SYSTEM HOSE VALVE (LSPV) OPERATION ................. 04-11-4
ROUTING DIAGRAM [WL-3] ................ 01-13A-2 LUBRICATION SYSTEM
II
INTAKE AIR SYSTEM HOSE FLOW DIAGRAM [WL-3] ................... 01-11A-2
ROUTING DIAGRAM [WL-C, WE-C]. ......... 01-13B-2 LUBRICATION SYSTEM
INTAKE AIR SYSTEM OUTLINE [WL-3] ........ 01-13A-1 FLOW DIAGRAM [WL-C, WE-C] ............. 01-11B-3
INTAKE AIR SYSTEM OUTLINE LUBRICATION SYSTEM OUTLINE [WL-3] ...... 01-11A-1 '
[WL-C, WE-C] ........................... 01-13B-1 LUBRICATION SYSTEM OUTLINE
INTAKE AIR SYSTEM STRUCTURAL [WL-C, WE-C] ........................... 01-11B-1
VIEW [WL-3] ............................ 01-13A-1 LUBRICATION SYSTEM STRUCTURAL
INTAKE AIR SYSTEM STRUCTURAL VIEW [WL-3] ............................ 01-11A-1
VIEW [WL-C, WE-C] ...................... 01-13B-2 LUBRICATION SYSTEM STRUCTURAL
VIEW [WL-C, WE-C] ...................... 01-11B-2
AI-5
ALPHABETICAL INDEX
OIL PAN CONSTRUCTION [WL-C, WE-C] ..... 01-11B-4
M OIL PUMP CONSTRUCTION [WL-3] .......... 01-11A-4

OIL PUMP CONSTRUCTION [WL-C, WE-C] .... 01-11 B-5
OIL STRAINER CONSTRUCTION
MAGNETIC CLUTCH CONSTRUCTION ......... 07-40-3 [WL-C, WE-C] ........................... 01-118-5
MANUAL AIR CONDITIONER OIL STRAINER CONSTRUCTION [WL-3] ...... 01-11A-4
CONTROL SYSTEM ....................... 07-40-4 ON-BOARD DIAGNOSTIC FUNCTION
MANUAL TRANSMISSION OUTLINE [AI R BAG SYSTEM] . . . . . . . . . . . . . . . . . . . . . . . 08-02-1
[R15M-D] ...............................05-11A-1 ON-BOARD DIAGNOSTIC OUTLINE
MANUAL TRANSMISSION OUTLINE [WL-C, WE-C] .......................... 01-02B-1
[S15M-D, S15MX-D] ....................... 05-11B-1 ON-BOARD DIAGNOSTIC OUTLINE [WL-3] .... 01-02A-1
MANUAL TRANSMISSION POWER ON-BOARD DIAGNOSTIC OUTLINE
FLOW [S15M-D, S15MX-D] .................05-11B-3 [REMOTE FREEWHEEL (RFW)] ............. 03-02-1
MANUAL TRANSMISSION ON-BOARD DIAGNOSTIC FUNCTION
CROSS-SECTIONAL VIEW OUTLINE ............................... 08-02-1
[S15M-D, S15MX-D] ....................... 05-11 B-2 ON-BOARD DIAGNOSTIC SYSTEM ACTIVE
MANUAL TRANSMISSION COMMAND MODES FUNCTION [4W-ABS] ... 04-02B-3
CROSS-SECTIONAL VIEW [R15M-D] ......... 05-11 A-1 ON-BOARD DIAGNOSTIC SYSTEM
MANUAL TRANSMISSION EXTERNAL TESTER COMMUNICATION
POWER FLOW [R15M-D] ..................05-11A-2 FUNCTION [4W-ABS] ..................... 04-02B-4
MASS AIR FLOW (MAF) SENSOR ON-BOARD DIAGNOSTIC SYSTEM
CONSTRUCTION/OPERATION FUNCTION [4W-ABS] ..................... 04-02B-2
[WL-C, WE-C] ..........................01-40B-20 ON-BOARD DIAGNOSTIC SYSTEM
MASS AIR FLOW (MAF) SENSOR FUNCTION [REAR ABS] ................. , 04-02A-1
CONSTRUCTION/OPERATION [WL-3] ....... 01-40A-15 ON-BOARD DIAGNOSTIC SYSTEM
MASS AI R FLOW (MAF) SENSOR OUTLINE [4W-ABS] ...................... 04-02B-1
FUNCTION [WL-3] ....................... 01-40A-14 ON-BOARD DIAGNOSTIC SYSTEM
MASS AIR FLOW (MAF) SENSOR OUTLINE [REAR ABS] .................... 04-02A-1
FUNCTION [WL-C, WE-C] .................01-40B-20 ON-BOARD DIAGNOSTIC SYSTEM
MASTER CYLINDER CONSTRUCTION ......... 04-11-2 PID/DATA MONITOR FUNCTION [4W-ABS] ... 04-02B-3
MEMORY FUNCTION [WL-3] ................01-02A-4 ON-BOARD DIAGNOSTIC SYSTEM
MMINTAKE AIR TEMPERATURE (IAT) [IMMOBILIZER SYSTEM] .................. 09-14-11
SENSOR NO.1 CONSTRUCTION/ ON-BOARD DIAGNOSTIC SYSTEM
OPERATION [WL-3] ...................... 01-40A-17 FUNCTION ... " ....................... " 09-20-6
MULTIPLE FUEL INJECTION CONTROL ON-BOARD DIAGNOSTIC SYSTEM OUTLINE. " 09-20-6
BLOCK DIAGRAM [WL-C, WE-C] ........... 01-40B-15 OVERFLOW VALVE CONSTRUCTION [WL-3] .. 01-14A-6
MULTIPLE FUEL INJECTION CONTROL OVERFLOW VALVE FUNCTION [WL-3] ....... 01-14A-6
OPERATION [WL-C, WE-C] ................01-40B-15 OXIDATION CATALYTIC CONVERTER
MULTIPLE FUEL INJECTION CONSTRUCTION [WL-3] .................. 01-16A-6
CONTROL OUTLINE [WL-C, WE-C] ......... 01-40B-15 OXIDATION CATALYTIC CONVERTER
CONSTRUCTION [WL-C, WE-C] ............ 01-16B-7
N II OXIDATION CATALYTIC
CONVERTER FUNCTION [WL-3] ........... 01-16A-6
NEUTRAL SWITCH CONSTRUCTION/ FUNCTION [WL-C, WE-C] ................. 01-16B-6
OPERATION [WL-C, WE-C] ................ 01-40B-28 OXIDATION CATALYTIC CONVERTER
NEUTRAL SWITCH FUNCTION OPERATION [WL-3] ...................... 01-16A-6
[WL-C, WE-C] ........................... 01-40B-28 OXIDATION CATALYTIC CONVERTER
NEUTRAL SWITCH FUNCTION [WL-3] ........ 01-40A-24 OPERATION [WL-C, WE-C] ................ 01-16B-7
NEUTRAL SWITCH OPERATION [WL-3] ...... 01-40A-24
NEW STAN DARDS ........................ 00-0()-'14 II . p I
II 0 II PARKING BRAKE SYSTEM OUTLlNE. ......... 04-12-1

OIL COOLER, OIL FILTER BODY
STRUCTURAL VIEW .................... " 04-12-1
CONSTRUCTION [WL-3] ................... 01-11A-3
PASSENGER-SIDE AIR BAG MODULE
OIL COOLER, OIL FILTER BODY
CONSTRUCTION/OPERATION ............ " 08-10-5
CONSTRUCTION [WL-C, WE-C] ............. 01-11B-4
PASSENGER-SIDE AIR BAG MODULE
OIL FILTER CONSTRUCTION [WL-3] .......... 01-11A-2
FUNCTION ............................ " 08-10-5
OIL FILTER CONSTRUCTION [WL-C, WE-C] .... 01-11 B-3
PCM CONSTRUCTION [WL-3] .............. 01-40A-14
OIL JET VALVE CONSTRUCTION/
PCM CONSTRUCTION [WL-C, WE-C] ........ 01-40B-19
OPERATION [WL-C, WE-C] .................01-11B-6
PCM FUNCTION [WL-3] ................... 01-40A-14
OIL JET VALVE
PCM FUNCTION [WL-C, WE-C] ............. 01-40B-19
CONSTRUCTION/OPERATION [WL-3] ........ 01-11A-5
OIL PAN CONSTRUCTION [WL-3] ............ 01-11A-3
AI-6
ALPHABETICAL INDEX
PID/DATA MONITOR AND RECORD REMOTE FREEWHEEL (RFW) OUTLINE ........ 03-18-1
[WL-C, WE-C] .......................... 01-02B-15 RESISTOR CONSTRUCTION ................. 07-40-3
PID/DATA MONITOR AND RECORD [WL-3] .... 01-02A-7 RESONANCE CHAMBER OUTLINE [WL-3] ..... 01-13A-7
PISTON CONSTRUCTION [WL-C, WE-C] ...... 01-10B-4 RESTRAINTS ABBREVIATIONS ............... 08-00-1
PISTON, PISTON RING, PISTON PIN RESTRAINTS FEATURES .................... 08-00-1
CONSTRUCTION [WL-3] .................. 01-10A-5 REVERSE LOCKOUT MECHANISM
POWER BRAKE UNIT CONSTRUCTION ........ 04-11-2 CONSTRUCTION/OPERATION [R15M-D] ..... 05-11A-6
POWER OUTER MIRROR OUTLINE ........... 09-12-3 REVERSE LOCKOUT MECHANISM
POWER OUTER MIRROR SYSTEM CONSTRUCTION/OPERATION
WIRING DIAGRAM ........................ 09-12-4 [S15M-D, S15MX-D] ...................... 05-11B-8
POWER OUTER MIRROR OPERATION ........ 09-12-5 REVERSE LOCKOUT MECHANISM
POWER OUTER MIRROR FUNCTION [R15M-D] ..................... 05-11A-6
STRUCTURAL VIEW ...................... 09-12-4 REVERSE LOCKOUT MECHANISM
POWER STEERING OIL PUMP FUNCTION [S15M-D, S15MX-D] ............. 05-11B-8
CONSTRUCTION ......................... 06-14-4 ROLLOVER VALVE
POWER STEERING OUTLINE ................ 06-14-1 CONSTRUCTION/OPERATION [WL-3] ....... 01-16A-6
POWER STEERING STRUCTURAL VIEW ....... 06-14-2 ROLLOVER VALVE
POWER SYSTEMS STRUCTURA VIEW ........ 09-21-1 CONSTRUCTION/OPERATION
POWER WINDOW SYSTEM OUTLINE ......... 09-12-2 [WL-C, WE-C] ........................... 01-16B-7
POWER WINDOW SYSTEM OPERATION ....... 09-12-3 ROLLOVER VALVE FUNCTION [WL-3] ........ 01-16A-6
POWER WINDOW SYSTEM ROLLOVER VALVE FUNCTION [WL-C, WE-C] .. 01-16B-7
s
STRUCTURAL VIEW ...................... 09-12-2
POWER WINDOW SYSTEM
WIRING DIAGRAM ........................ 09-12-3
CONSTRUCTION/OPERATION .............. 08-10-7 SAS CONTROL MODULE
PRE-TENSIONER SEAT BELT FUNCTION ...... 08-10-6 CONSTRUCTION/OPERATION .............. 08-10-3
SAS CONTROL MODULE FUNCTION .......... 08-10-3
R SEAT BELT OUTLINE ....................... 08-11-1

SEAT BELT STRUCTURAL ViEW .............. 08-11-1
SEATS OUTLINE ........................... 09-13-1
RADIATOR, COOLING SYSTEM CAP SEATS SPECIFICATION ..................... 09-13-1
CONSTRUCTION [WL-3] .................. 01-12A-2 SEATS STRUCTURAL VIEW ................. 09-13-2
RADIATOR, COOLING SYSTEM CAP SECURITY AND LOCKS OUTLINE ............. 09-14-1
CONSTRUCTION [WL-C, WE-C] ............ 01-12B-2 SHIFT INTERLOCK MECHANISM
REAR AXLE OUTLINE ...................... 03-12-1 FUNCTION [R15M-D] ..................... 05-11A-5
REAR AXLE CROSS-SECTIONAL VIEW ........ 03-12-1 SHIFT INTERLOCK MECHANISM
REAR BRAKE (DRUM) CONSTRUCTION ....... 04-11-7 FUNCTION [S15M-D, S15MX-D] ............. 05-11B-7
REAR BRAKE (DRUM) OPERATION ........... 04-11-8 SHIFT INTERLOCK MECHANISM
REAR COMBINATION LIGHT OPERATION [R15M-D] .................... 05-11A-5
STRUCTURAL VIEW ...................... 09-18-4 SHIFT INTERLOCK MECHANISM
REAR DIFFERENTIAL OPERATION [S15M-D, S15MX-D] ........... 05-11B-7
CROSS-SECTIONAL VIEW ................. 03-14-1 SHIFT MECHANISM OUTLINE
REAR DIFFERENTIAL OUTLINE .............. 03-14-1 [S15M-D, S15MX-D] ...................... 05-11 B-4
REAR SUSPENSION OUTLINE ............... 02-14-1 SHIFT MECHANISM STRUCTURE [R15M-D] .... 05-11A-3
REAR SUSPENSION STRUCTURAL ViEW ...... 02-14-1 SIDE AIR BAG MODULE FUNCTION ........... 08-10-5
REAR WINDOW DEFROSTER SYSTEM SIDE AIR BAG MODULE
OPERATION ............................. 09-12-2 CONSTRUCTION/OPERATION .............. 08-10-6
REAR WINDOW DEFROSTER SYSTEM SIMULATION TEST [WL-3] .................. 01-02A-8
WIRING DIAGRAM ........................ 09-12-1 SIMULATION TEST [WL-C, WE-C] ........... 01-02B-16
REAR WINDOW DEFROSTER OUTLINE ....... 09-12-1 SPEEDOMETER CONTROL
REAR WINDOW DEFROSTER CONSTRUCTION/OPERATION .............. 09-22-7
STRUCTURAL VIEW ...................... 09-12-1 SPEEDOMETER CONTROL OUTLINE .......... 09-22-7
REFRIGERANT LINE CONSTRUCTION ........ 07-11-5 STARTER CONSTRUCTION
REFRIGERANT PRESSURE SWITCH [WL-3, WL-C, WE-C] ....................... 01-19-1
CONSTRUCTION ......................... 07-40-4 STARTING SYSTEM OUTLINE
REMOTE FREEWHEEL (RFW) [WL-3, WL-C, WE-C] ....................... 01-19-1
COMPONENTS AND FUNCTIONS ........... 03-18-2 STARTING SYSTEM STRUCTURAL
III
REMOTE FREEWHEEL (RFW)
CONSTRUCTION ......................... 03-18-1
REMOTE FREEWHEEL (RFW) OPERATION .... 03-18-4
VIEW [WL-3, WL-C, WE-C] .................. 01-19-1
STEERING ABBREVIATION .................. 06-00-1
STEERING FEATURES ...................... 06-00-1
IiiII
REMOTE FREEWHEEL (RFW) STEERING GEAR AND LINKAGE
SYSTEM DIAGRAM ....................... 03-18-3 CONSTRUCTION ......................... 06-14-3
REMOTE FREEWHEEL (RFW) STEERING SHAFT CONSTRUCTION .......... 06-14-5
SYSTEM WIRING DIAGRAM ................ 03-18-4 STEERING SPECIFICATIONS ................ 06-00-1
AI-7
..,
ALPHABETICAL INDEX
TURBOCHARGER FUNCTION [WL-C, WE-C] .. 01-13B-5
I
SUPPLY PUMP CONSTRUCTION/
u
OPERATION [WL-C, WE-C] ................. 01-14B-5
SUPPLY PUMP FUNCTION [WL-C, WE-C] ...... 01-14B-5
SUSPENSION ABBREVIATIONS .............. 02-00-1
SUSPENSION FEATURES ................... 02-00-1
SUSPENSION SPECIFICATIONS .............. 02-00-2 UNITS .................................. 00-00-13
~===T==~III~I====V==~
TACHOMETER CONTROL OUTLINE ........... 09-22-8 VACUUM CHAMBER FUNCTION
TACHOMETER CONTROL [WL-C, WE-C] .......................... 01-13B-7
CONSTRUCTION/OPERATION .............. 09-22-8 VACUUM CHECK VALVE
THEFT-DETERRENT SYSTEM CONDITION ..... 09-14-4 CONSTRUCTION [WL-C, WE-C] ............ 01-13B-8
THEFT-DETERRENT SYSTEM VACUUM CHECK VALVE FUNCTION
INPUT/OUTPUT DIAGRAM .................. 09-14-4 [WL-C, WE-C] ........................... 01-13B-7
THEFT-DETERRENT SYSTEM OUTLINE ........ 09-14-2 VACUUM PUMP CONSTRUCTION ............ 04-11-2
THEFT-DETERRENT SYSTEM PHASE ......... 09-14-5 VALVE MECHANISM STRUCTURAL
THEFT-DETERRENT SYSTEM VIEW [WL-3] ............................ 01-10A-7
STRUCTURAL VIEW ....................... 09-14-3 VALVE MECHANISM STRUCTURAL
THEFT-DETERRENT SYSTEM VIEW [WL-C, WE-C] ...................... 01-10B-6
SYSTEM WIRING DIAGRAM ................. 09-14-3 VALVE, ROCKER ARM
THERMOSTAT CONSTRUCTION/ CONSTRUCTION [WL-3] .................. 01-10A-9
OPERATION [WL-3] ....................... 01-12A-3 VALVE, ROCKER ARM
THERMOSTAT CONSTRUCTION/ CONSTRUCTION [WL-C, WE-C] ............ 01-10B-9
OPERATION [WL-C, WE-C] .................01-12B-3 VARIABLE BOOST CONTROL (VBC)
TIMER CONTROL VALVE (TCV) SOLENOID VALVE CONSTRUCTION
CONSTRUCTION/OPERATION [WL-3] ........ 01-14A-8 [WL-C, WE-C] ........................... 01-13B-3
TIMER CONTROL VALVE (TCV) VARIABLE BOOST CONTROL (VBC)
FUNCTION [WL-3] ........................01-14A-8 SOLENOID VALVE FUNCTION
TIMER POSITION SENSOR [WL-C, WE-C] ........................... 01-13B-3
CONSTRUCTION/OPERETION [WL-3] ...... 01-40A-22 VEHICLE IDENTIFICATION NUMBER
TIMER POSITION SENSOR (VIN) CODE ............................ 00-00-12
I
FUNCTION [WL-3] .......................01-40A-21 VEHICLE IDENTIFICATION NUMBERS (VIN) ... 00-00-12
TIMING GEAR CONSTRUCTION [WL-3] ....... 01-10A-8
TIMING GEAR CONSTRUCTION
[WL-C, WE-C] ...........................01-10B-6
TRANSFER OUTLINE ....................... 03-16-1
w
WASHER TANK SPECIFICATION ............. 09-19-4
TRANSFER POWER FLOW .................. 03-16-2
WATER PUMP CONSTRUCTION/
TRANSFER CROSS-SECTIONAL VIEW ......... 03-16-1
OPERATION [WL-3] ...................... 01-12A-3
TRANSMISSIONITRANSAXLE
WATER PUMP CONSTRUCTION/
ABBREVIATIONS ......................... 05-00-1
OPERATION [WL-C, WE-C] ................ 01-12B-3
TRANSMISSIONITRANSAXLE FEATURES ...... 05-00-1
TRANSMISSIONITRANSAXLE
CONTROL CONSTRUCTION/
SPECIFICATIONS ......................... 05-00-1
OPERATION ............................. 09-22-9
TRIPLE CONE SYNCHRONIZER
MECHANISM OPERATION
CONTROL OUTLINE ...................... 09-22-9
[S15M-D, S15MX-D] ....................... 05-11B-5
WHEEL AND TIRES OUTLINE ................ 02-12-1
TRIPLE CONE SYNCHRONIZER
WHEEL AND TIRES STRUCTURAL VIEW ...... 02-12-1
MECHANISM STRUCTURE
WIPER SYSTEM OPERATION ................ 09-19-2
[S15M-D, S15MX-D] ....................... 05-118-5
WIPER SYSTEM OUTLINE .................. 09-19-1
TURBOCHARGER CONSTRUCTION [WL-3] .... 01-13A-3
WIPER SYSTEM WIRING DIAGRAM ........... 09-19-2
TURBOCHARGER CONSTRUCTION/
WIPERIWASHER SYSTEM OUTLINE .......... 09-19-1
OPERATION [WL-C, WE-C] ................. 01-13B-5
WIPERIWASHER SYSTEM
TURBOCHARGER DESCRIPTION [WL-3] ......01-13A-4
STRUCTURAL VIEW ...................... 09-19-1
TURBOCHARGER FUNCTION [WL-3] ......... 01-13A-3
AI-8
SERVICE
PROCEDURES
WARNING
Servicing a vehicle can be dangerous. If you have not received
service-related training, the risks of injury, property damage, and
failure of servicing increase. The recommended servicing
procedures for the vehicle in this workshop manual were
developed with Ford-trained technicians in mind. This manual
may be useful to non-Ford trained technicians, but a technician
with our service-related training and experience will be at less
risk when performing service operations. However, all users of
this manual are expected to at least know general safety
procedures.
This manual contains "Warnings" and "Cautions" applicable to

risks not normally encountered in a general technician's
experience. They should be followed to reduce the risk of injury
and the risk that improper service or repair may damage the
vehicle or render it unsafe. It is also important to understand that
the "Warnings" and "Cautions" are not exhaustive. It is
impossible to warn of all the hazardous consequences that might
result from failure to follow the procedures.
The procedures recommended and described in this manual are

effective methods of performing service and repair. Some require
tools specifically designed for a specific purpose. Persons using
procedures and tools which are not recommended by Ford Motor
Company must satisfy themselves thoroughly that neither
personal safety nor safety of the vehicle will be jeopardized.
The contents of this manual, including drawings and

specifications, are the latest available at the time of printing, and
Ford Motor Company reserves the right to change the vehicle
designs and alter the contents of this manual without notice and
without incurring obligation.
Parts should be replaced with genuine Ford replacement parts or

with parts which match the quality of genuine Ford replacement
parts. Persons using replacement parts of lesser quality than that
of genuine Ford replacement parts must satisfy themselves
thoroughly that neither personal safety nor safety of the vehicle
will be jeopardized.
Ford Motor Company is not responsible for any problems which

may arise from the use of this manual. The cause of such
problems includes but is not limited to insufficient service-
related training, use of improper tools, use of replacement parts
of lesser quality than that of genuine Ford replacement parts, or
not being aware of any revision of this manual.
VEHICLE IDENTIFICATION NUMBERS (VIN)
MNA BS******
MNA DS****** i.
MNA LS******
MNA US******
RELATED MATERIALS
RANGER Training Manual ....................... F340-10-0SL

RANGER Overhaul Manual ...................... F198-20-0SL
RANGER Body Measurement Chart Manual ........ F34D-20-0SL
RANGER Wiring Diagrams....................... F198-30-0SL
PJ Ranger
Overhaul Manual
(Part No. OHM380)
WARNING
Servicing a vehicle can be dangerous. If you have not received
service-related training, the risks of injury, property damage, and
failure of servicing increase. The recommended servicing
procedures for the vehicle in this workshop manual were
developed with Ford-trained technicians in mind. This manual
may be useful to.non-Ford trained technicians, but a technician
with our service-related training and experience will be at less
risk when performing service operations. However, all users of
this manual are expected to at least know general safety
procedures.
This manual contains "Warnings" and "Cautions" applicable to

risks not normally encountered in a general technician's
experience. They should be followed to reduce the risk of injury
and the risk that improper service or repair may damage the
vehicle or render it unsafe. It is also important to understand that
the "Warnings" and "Cautions" are not exhaustive. It is
impossible to warn of all the hazardous consequences that might
result from failure to follow the procedures.
The procedures recommended and described in this manual are

effective methods of performing service and repair. Some require
tools specifically designed for a specific purpose. Persons using
procedures and tools which are not recommended by Ford Motor
Company must satisfy themselves thoroughly that neither
personal safety nor safety of the vehicle will be jeopardized.
The contents of this manual, including drawings and

specifications, are the latest available at the time of printing, and
Ford Motor Company reserves the right to change the vehicle
designs and alter the contents of this manual without notice and
without incurring obligation.
Parts should be replaced with genuine Ford replacement parts or

with parts which match the quality of genuine Ford replacement
parts. Persons using replacement parts of lesser quality than that
of genuine Ford replacement parts must satisfy themselves
thoroughly that neither personal safety nor safety of the vehicle
will be jeopardized.
Ford Motor Company is not responsible for any problems which

may arise from the use of this manual. The cause of such
problems includes but is noflimited to insufficient service-
related training, use of improper tools, use of replacement parts
of lesser quality than that of genuine Ford replacement parts, or
not being aware ofany revl.sion of this manual.
,£
CONTENTS
Title
GENERAL INFORMATION
RANGER ENGINE
Overhaul DRIVE LINE/AXLE

TRANSMISSIONI
Manual TRANSAXLE
© 2005 Ford Sales & Sarvice (Thailand) Co., Ltd.
• ENGINE PRINTED IN THAILAND, DECEMBER 2005
• MANUAL TRANSMISSION F198-20-05L
FOREWORD
This Manual explains the disassembly,

inspection, repair, and reassembly
procedures for the above-indicated engines
and manual transmissions. In order to do
these procedures safely, quickly, and
correctly, you must first read this manual and
any other relevant service materials carefully.
The information in this manual is current
up to DECEMBER 2005. Any changes that
occur after that time will not be reflected in
this particular manual. Therefore, the
contents of this manual may not exactly
match the mechanism that you are currently
servicing.
Ford Motor Company

GENERAL INFORMATION 00 m
SECTION
e GENERAL INFORMATION . .. 00-00

HOW TO USE THIS MANUAL. ..•..••. 00-00-2 ELECTRICAL SYSTEM ••.•...••..•.. 00-00-9
UNITS ..•••...•••..••.••...•••... 00-00-5 NEW STANDARDS .••••••....•••.••. 00-00-10
FUNDAMENTAL PROCEDURES ..•••. 00-00-5 ABBREVIATIONS ....•••.......•..•. 00-00-12
)! e
00-00-1
GENERAL INFORMATION
HOW TO USE THIS MANUAL
DCFOOOOOOOOOW01
Range of Topics
• This manual contains procedures for performing all required service operations. The procedures are divided
into the following five basic operations:
t· .
Removal/Installation
Disassembly/Assembly
Replacement
Inspection
Adjustment
• Simple operations which can be performed easily just by looking at the vehicle (Le., removal/installation of
parts, jacking, vehicle lifting, cleaning of parts, and visual inspection) have been omitted.
Service Procedure
Inspection, adjustment
• Inspection and adjustment procedures are
divided into steps. Important points regarding the SHOWS PROCEDURE ORDER
location and contents of the procedures are FORSE VICE
explained in detail and shown in the illustrations.
: SHOWS TIGHTENING
_ -.. TORQUE
SPECIFICATIONS
Connect the gauge set from under
the vehicle to prevent contact with
the drive belt and the cooling fan.
WGIWXX0009E
00-00-2
GENERAL INFORMATION
Repair procedure
1. Most repair operations begin with an overview illustration. It identifies the components, shows how the parts fit
e together, and describes visual part inspection. However, only removal/installation procedures that need to be
performed methodically have written instructions.
2. Expendable parts, tightening torques, and symbols for oil, grease, and sealant are shown in the overview
illustration. In addition, symbols indicating parts requiring the use of special service tools or equivalent are also
shown.
3. Procedure steps are numbered and the part that is the main point of that procedure is shown in the illustration
with the corresponding number. Occasionally, there are important points or additional information concerning a
procedure. Refer to this information when servicing the related part.
SHOWS SERVICE
Procedure ITEM (S)
... INDICATES ANY RELEVANT
"U
r
LOWER TRAILING LINK UPPER TRAILING LINK REMOVALIINSTALLATION REFERENCES WHICH NEED
"R III t II t' 1.Jack up the rear 01 the vehicle and support it with saletystands. TO BE FOLLOWED DURING
emova ns a a Ion 2. Remove the undercover. (See 01-10·4 Undercover Removal
Portion 3. Remove in the order indicated In the table. INSTALLATION
4. Install in the reverse order 01 removal.
'~I~-~~~~;i~~- ~-~~; - - - - , - '-- 5. Inspect the rear wheel alignment and a~djust
it il necessary. SHOWS SPECIAL
Installation" Portion 1 ~ SERVICE TOOL (SST)
SHOWS PROCEDURE ORDER ~ =~ lil~OR SERVICE OPERATION
FOR SERVICE
. ~Ilm
\
iii
INSTALL THE PARTS BY \ ~ SHOWS APPLICATION
PERFORMING STEPS ~ Q-----® 43-56 {4.3-S.8.32-41) POINTS OF GREASE, ETC.
1---3 IN REVERSE ORDER SHOWSTIGHTENI~~'~'~1 ~
TORQUE ~
SPECIFICATIONS I.~ SHOWS NON-REUSEABLE PARTS
SHOWS DETAILS
94-116 (9.5-11.9, 59-86}

SHOWS TIGHTENING
SHOWS THERE CD iii TORQUE UNITS
ARE REFERRAL
NOTES FOR SERVICE N·m{kgf·rn,ft·lbf)
1 Split pin 7 SoUtoin

~ Nut 8 Nut
3 Qwertralln In al Oint 9 Upper trailing link ball joint
(See 02-14-5 Lower Trailing Link 8all Joint Removal Note) (See 02-14-5 Upper Trailing Link Ball Joint Removal Note)
4 Bo[t 10 Nut
5 LowertraiUn link 11 Upper trailing link
6 Dust boot (lower trailing link) 12 Dust boot (upper trailing link)
LowerTrailing Link Ball JOint, Upper Trailing Link UPPER TRAILING LINK
Ball Joint Removal Note
• Remove the ball joint using the SSTs.
SHOWS SPECIAL
SERVICE TOOL (SST)
NO.
SHOWS REFERRAL
NOTES FOR
SERVICE
BHEOOOOW104
00-00-3
GENERAL INFORMATION
Symbols
• There are eight symbols indicating oil, grease, fluids, sealant, and the use of SST or equivalent. These symbols
show application points or use of these materials during service.
Symbol Meaning Kind
"
-~ New appropriate
Apply oil engine oil or gear
oil
II
New appropriate
Apply brake fluid
brake fluid
New appropriate
II
Apply automatic
automatic
transaxle/
transaxle/
transmission fluid
transmission fluid
~A Appropriate
II Apply grease
grease
Appropriate
·~I Apply sealant
sealant
e Apply petroleum
jelly
Appropriate
petroleum jelly
iii Replace part

O-ring, gasket,
etc. t
ED Use SST or
equivalent
Appropriate tools
Advisory Messages
• You will find several Warnings, Cautions, Notes, Specifications and Upper and Lower Limits in this
manual.
Warning
• A Warning indicates a situation in which serious injury or death could result if the warning is ignored.
Caution
• A Caution indicates a situation in which damage to the vehicle or parts could result if the caution is ignored.
Note
• A Note provides added information that will help you to complete a particular procedure.
Specification
• The values indicate the allowable range when performing inspections or adjustments.
Upper and lower limits

• The values indicate the upper and lower limits that must not be exceeded when performing inspections or
adjustments.
00-00-4
m
GENERAL INFORMATION
UNITS
DCFOOOOOOOOOW02
Electric current A (ampere) N·m (Newton meter)
Electric power W (watt) kgf·m (kilogram force meter)
Electric resistance ohm Torque kgf·cm (kilogram force centimeter)
Electric voltage V (volt) ft·lbf (foot pound force)
mm (millimeter) in·lbf (inch pound force)
Length
in (inch) L (liter)
kPa (kilo pascal) US qt (U.S. quart)
Negative pressure mmHg (millimeters of mercury) Imp qt (Imperial quart)
inHg (inches of mercury) Volume ml (milliliter)
kPa (kilo pascal) cc (cubic centimeter)
kgf/cm 2 (kilogram force per square cu in (cubic inch)
Positive pressure
centimeter) fl oz (fluid ounce)
psi (pounds per square inch) g (gram)
Weight
Number of oz (ounce)
rpm (revolutions per minute)
revolutions

from these values.
Rounding Off

• an upper limit and rounded up if the 81 unit value is a lower limit. Therefore, converted values for the same 81
210-260 kPa {2.1-2.7 kgf/cm 2 , 30-38 psi}

270-310 kPa {2.7-3.2 kgf/cm 2 , 39-45 psi}
FUNDAMENTAL PROCEDURES
DCFOOOOOOOOOW03
Preparation of Tools and Measuring Equipment
• Be sure that all necessary tools and measuring
equipment are available before starting any work.
CHU0014W003
00-00-5
GENERAL INFORMATION
Special Service Tools
• Use special service tools or equivalent when they
are required.
WGIWXX0024E
Disassembly
• If the disassembly procedure is complex,
requiring many parts to be disassembled, all parts
should be marked in a place that will not affect
their performance or external appearance and
identified so that reassembly can be performed
easily and efficiently.
WGIWXX0027E
Inspection During Removal, Disassembly

• When removed, each part should be carefully
inspected for malfunction, deformation, damage
t':
,~
and other problems.
WGIWXX0028E
Arrangement of Parts
• All disassembled parts should be carefully
arranged for reassembly.
• Be sure to separate or otherwise identify the parts
to be replaced from those that will be reused.
WGIWXX0029E
00-00-6
GENERAL INFORMATION
Cleaning of Parts
• All parts to be reused should be carefully and
thoroughly cleaned in the appropriate method.
i'
Warning
• Using compressed air can cause dirt and
other particles to fly out causing injury to
the eyes. Wear protective eye wear
whenever using compressed air.
C5UOOOOW001
Reassembly
• Standard values, such as torques and certain
adjustments, must be strictly observed in the
reassembly of all parts.
• If removed, the following parts should be replaced
with new ones:
Oil seals
Gaskets
O-rings
Lockwashers
Cotter pins
Nylon nuts
WGIWXX0031E
• Depending on location:
Sealant and gaskets, or both, should be
applied to specified locations. When sealant
is applied, parts should be installed before
sealant hardens to prevent leakage.
Oil should be applied to the moving
components of parts.
Specified oil or grease should be applied at
the prescribed locations (such as oil seals)
before reassembly.
CHU0014W006
Adjustment
• Use suitable gauges and testers when making
adjustments.
CHU0014W005
00-00-7
GENERAL INFORMATION
Rubber Parts and Tubing
• Prevent gasoline or oil from getting on rubber
parts or tubing.
WGIWXX0034E
Hose Clamps
• When reinstalling, position the hose clamp in the
original location on the hose and squeeze the
clamp lightly with large pliers to ensure a good fit.
WGIWXX0035E
Torque Formulas
• When using a torque wrench-SST or equivalent ~------------------------~f
combination, the written torque must be 1mB
~=======1fp
recalculated due to the extra length that the SST
or equivalent adds to the torque wrench.
Recalculate the torque by using the following
formulas. Choose the formula that applies to you.
Torque Unit Formula
N·m N·m x [U (L+A)]
kgf·m kgf·m x [U (L+A)]
kgf·cm kgf·cm x [U (L+A)]
ft·lbf ft·lbf x [U (L+A)] WGIWXX0036E
in·lbf in·lbf x [U (L+A)]
A : The length of the SST past the torque wrench drive.

L : The length of the torque wrench.
Vise
• When using a vise, put protective plates in the
jaws of the vise to prevent damage to parts.
PROTECTIVE PLATES
CHU0014W010
00-00-8
m
GENERAL INFORMATION
ELECTRICAL SYSTEM
DCFOOOOOOOOOW04
Connectors
I
a Disconnecting connectors
. , . • When disconnecting connector, grasp the
connectors, not the wires. GOOD NO GOOD
• Connectors can be disconnected by pressing or

pulling the lock lever as shown.
WGIWXX0042E
Locking connector . .
• When locking connectors, listen for a click
indicating they are securely locked.
WGIWXX0043E
Inspection . .
• When a tester is used to inspect for continuity or
measuring voltage, insert the tester probe from GOOD NO GOOD
the wiring harness side.
00-00-9
GENERAL INFORMATION
• Inspect the terminals of waterproof connectors from the connector side since they cannot be accessed from the
wiring harness side.
Caution t)
• To prevent damage to the terminal, wrap r-------------------------~~----------_.
a thin wire around the tester probe before GOOD NO GOOD

inserting into terminal.
CHUOOOOW012
NEW STANDARDS
DCFOOOOOOOOOW05
Name Name
ation ation
B+ Battery Positive Voltage Vb Battery Voltage
CPP Clutch Pedal Position - Idle Switch
CIS Continuous Fuel Injection System - Clutch Position
FSO
solenoid
lAC Idle Air control - Idle Speed Control
00-00-10
GENERAL INFORMATION
II
Name Name
ation ation
- InputfTurbine Speed Sensor - Pulse Generator I
OBD On-Board Diagnostic - Diagnosis/SelfDiagnosis
- Output Speed Sensor - Vehicle Speed Sensor 1
Pulsed
injection
-
Injection
AIR Secondary Air Injection Secondary Air Injection System with air
.,
-
pump
- 12 Shift Solenoid Valve
- Shift Solenoid A
- Shift Solenoid B
- 23 Shift Solenoid Valve
- Shift Solenoid C - 34 Shift Solenoid Valve
<,
TCM
Module
- Temperature Sensor
- ATF Thermosensor
VAF sensor Volume Air Flow Sensor - Air flow Sensor
WUTWC
Converter
- Catalytic Converter #5
#1 : Diagnostic trouble codes depend on the diagnostic test mode

#2 : Controlled by the PCM '
#3 : In some models, there is a fuel pump relay that controls pump speed. That relay is now called the fuel pump
relay (speed).
#4 : Device that controls engine and powertrain
#5 : Directly connected to exhaust manifold
#6 : Part name of diesel engine
00-00-11
GENERAL INFORMATION
ABBREVIATIONS
DCFOOOOOOOOOW06
ATDC Aft er Top Dead Center
,
BTDC Before Top Dead Center
EX Ex haust
HLA Hydraulic Lash Adjuster
•
IN Intake
I: SST Special Service Tool
I: TDC To p Dead Center
I,i: VRS Vi bration Reducing Stiffener
VSS Ve hicle Speed Sensor
4x2 4-wheel 2-d rive
4x4 4-wheel 4-drive
!,
'I:
I'
Ii
i!
I
Ii
I
I .
• 1::
':
i
!
'i
!,
!
00-00-12
I
ENGINE 01
e .
SECTION
~!
MECHANICAL [WL-3] ....... 01-10A
MECHANICAL
TECHNICAL DATA
[WL-C, WE-C] ............. 01-508
IiII
[WL-C, WE-C] . . . . . . . . . . . . 01-108 SERVICE TOOLS [WL-3] ..... 01-60A
TECHNICAL DATA [WL-3] . . . 01-50A SERVICE TOOLS
[WL-C, WE-C] ............. 01-608
01-10A MECHANICAL [WL-3]

ENGINE MOUNTING [WL-3] ..•......• 01-10A-2, CRANKSHAFT INSPECTION [WL-3] ..• 01-10A-25
ENGINE DISMOUNTING [WL-3] .•••... 01-10A-3 CRANKSHAFT OIL CLEARANCE
TIMING BELT DISASSEMBLY [WL-3] .. 01-10A-4 INSPECTION/REPAIR [WL-3] ...••••• 01-10A-26
CYLINDER HEAD CRANKSHAFT END PLAY
DISASSEMBLY(I) [WL-3] .••.•..•..• 01-10A-6 INSPECTION/REPAIR [WL-3] •.....•. 01-1 OA-26
CYLINDER HEAD DISASSEMBLY (II) CONNECTING ROD INSPECTION
[WL-3] •...•••.••••.••.••....••.. 01-10A-8 [WL-3] ..•.........•.....•.•...... 01-1 OA-26
CYLINDER BLOCK DISASSEMBLY (I) CONNECTING ROD OIL CLEARANCE
[WL-3] •...•.......•••••........• 01-10A-9 INSPECTION/REPAIR [WL-3] ....••.. 01-1 OA-27
CYLINDER BLOCK DISASSEMBLY (II) CONNECTING ROD SIDE CLEARANCE
[WL-3] ...•...•....... " ...••.•.. 01-10A-10 INSPECTION [WL-3] •••..••••.....• 01-10A-27
CYLINDER BLOCK DISASSEMBLY (III) PISTON AND CONNECTING ROD
[WL-3] ...•..•....•..•....••••••. 01-10A-15 INSPECTION [WL-3] .••...••••..... 01-10A-28
CYLINDER HEAD INSPECTION/REPAIR BOLT INSPECTION [WL-3] ••..•••.•.. 01-10A-28
, . [WL-3] ....•••.•••••••.••••..•••. 01-10A-16 TENSIONER SPRING INSPECTION
• VALVE INSPECTION [WL-3] •••......• 01-10A-17 [WL-3] ..•.........•..•..•...•.•.. 01-1 OA-28
VALVE GUIDE INSPECTION [WL-3] ••. 01-10A-18 VALVE CLEARANCE INSPECTION
VALVE GUIDE REPLACEMENT [WL-3]. 01-10A-19 [WL-3] ....••..•......•••....••.•• 01-1 OA-29
VALVE SEAT VALVE CLEARANCE. ADJUSTMENT
INSPECTION/REPAIR [WL-3] ..•••••. 01-10A-19 [WL-3] .•.••.••.•••.••..•.•••...•• 01-1 OA-29
VALVE SPRING INSPECTION [WL-3] •. 01-10A-20 INJECTION TIMING ADJUSTMENT
CAMSHAFT INSPECTION [WL-3] ...•• 01-10A-21 [WL-3] ......•.....•••....•••..•.. 01-1 OA-30
CAMSHAFT OIL CLEARANCE GEAR CLEARANCE INSPECTION
INSPECTION [WL-3] ..•..••••.....• 01-10A-21 [WL-3] ..•...............•...•••.. 01-10A-32
CAMSHAFT END PLAY PLUNGER SPRING INSPECTION,
INSPECTION [WL-3] .•...•..•••... '. 01-10A-22 [WL-3] ....••..•......•••....••.•• 01-1 OA-32
CYLINDER BLOCK CYLINDER BLOCK ASSEMBLY (I)
INSPECTION/REPAIR [WL-3] ..• , •••. 01-10A-22 [WL-3] .•.•.•••.•••.••.••.. ';..•.•. 01-1 OA-33
OIL JET VALVE, NOZZLE CYLINDER BLOCK ASSEMBLY (II)
INSPECTION [WL-3] ..••.•..•..•... 01-10A-23 [WL-3] •.•...•.......•....•••..... 01-1 OA-36
PISTON INSPECTION [WL-3] .••...•.. 01-10A-23 CYLINDER BLOCK ASSEMBLY (III)
PISTON CLEARANCE [WL-3] ..•.....•...••....••..•••.. 01-1 OA-42
INSPECTION/REPAIR [WL-3] .•.•.•.• 01-10A-23 CYLINDER HEAD ASSEMBLY (I)
PISTON RING CLEARANCE [WL-3] .....•..•......•••.....•.•• 01-1 OA-44
INSPECTION [WL-3] ••..•....•••••. 01-10A-23 CYLINDER HEAD ASSEMBLY (II)
PISTON PIN CLEARANCE [WL-3] .•.•••••.•••..•..•..•...... 01-1 OA-46
INSPECTION [WL-3] ...•..••.•.•••. 01-10A-24 TIMING BELT ASSEMBLY [WL-3] .. " .• 01-10A-51
01-10A-1
MECHANICAL [WL-3]
ENGINE MOUNTING [WL-3]
DCF011002000W01
1. Install the engine hanger (JE48 10 561 C) or SST
JE48 10561 C or SST (303-050 (49 UN30 3050))
(303-050 (49 UN30 3050)) to the cylinder head
using the bolt (99794 0820 or M8X1.25, ST,
length 20mm {O.79 in}) as shown in the figure.
Tightening torque
18.S-25.5 N·m {1.90-2.S0 kgf·m, 13.8-18.8
ft· Ibf}
BOLT
DBG110AEBR01
2. If the SST (303-050 (49 UN30 3050)) is used, use

the SST (49 L017 5AO) when suspending the
engine.
~W~~~~-M8x1.25
BOLT
DBG110AEBR84
3. Install the SST (arms) to the holes as shown in

the figure, and hand tighten the SST (bolts).
4. Assemble the SSTs (bolts, nuts and plate) to the

specified positions.
DBG110AEB003
01-10A-2
MECHANICAL [WL-3]
5. Adjust the SST (bolts) so that 20 mm {0.79 in} or
more of thread is exposed.
6. Align the SSTs (plate and arms) so that they are
II
parallel by adjusting the SSTs (bolts and nuts).
7. Tighten the SSTs (bolts and nuts) to affix the SST
firmly.
8. Mount the engine on the SST (engine stand). ENGINE
Warning
• The self-locking brake system for the
engine stand may not operate if the
engine is held in an unbalanced position.
DBG110AEB105
This could lead to sudden, rapid
movement of the engine and mounting
stand handle and cause serious injury. Never hold the engine in an unbalanced position, and
always grasp the rotating handle firmly when turning the engine.
9. Remove the engine hanger (JE48 10561 C) or

SST (303-050 (49 UN30 3050)).
10. Drain the engine oil into a container.
11. Install the drain plug using new washer.
Tightening torque
29.4-41.2 N·m {3.00-4.20 kgf·m, 21.7-30.3
ft.lbf}
DBG110AEB004
e ENGINE DISMOUNTING [WL-3]

1. Dismount in the reverse order of mounting.
DCF011002000W02
01-10A-3
TIMING BELT DlSASSE MECHANICAL [WL-3]
1. Disassembl' MBLY [WL-3] DCF011002000W03
er shown in the f'Igure.
_ ____~~e~~In~t~he~or~der~
---=---L.W
.. :a~t"er pump 6 (se:I~~=r1' tensioner sprin
Ten' DBG110AEBR05
Vacuum pump D'.Isassembly

OA-5 Te'
Note )sloner,g Tensioner S .
3 Cylinder
T . head cover Timing b e l t ' pnng
Imlng belt cover
pUlley:np;J;la+,:;te---..:....:...~-
__ -5 Timing
-L.:..(S:::.:e::e~O~1-~1~OA~2i·m ~ls~as~s~em~~bl~~N~L_...
Belt D'
_ ____ ote.) I
01-10A-4
MECHANICAL [WL-3]
-
Tensioner, Tensioner Spring Disassembly Note
1. Turn the crankshaft clockwise and align the timing --TIMING MARK
marks as shown in the figure.
CAMSHAFT
~. PULLEY
TENSIONER
SPRING
TENSIONER
+---- FUEL INJECTION PUMP
PULLEY
DBG110AEBR11
Timing Belt Disassembly Note

1. Mark the timing belt rotation on the belt for proper
reinstallation.
Caution
• The following will damage the timing belt
~~~
~ROTATION
and shorten its life; forcefully twisting it,
turning it inside out, or getting oil or
grease on it.
• After removing the timing belt, do not
move the crankshaft and/or camshaft
~I ~ ARROW
NG
pulley from this position because it can 30 mm {1.2 in } MIN.
cause the valve and piston to contact and
DBG110AEBR10
damage them .
'•\.
01-10A-5
MECHANICAL [WL-3]
CYLINDER HEAD DISASSEMBLY(I) [WL-3]
DCF011002000W04
1. Disassemble in the order shown in the figure.
LOWER CAP IS MACHINED TOGETHER WITH

CYLINDER HEAD AND CANNOT BE REMOVED
8
10 11 iii
DBG110AEBR08
1 Camshaft pulley 5 Rocker arm

(See 01-10A-7 Camshaft Pulley Disassembly 6 Water temperature sender unit
Note.)
7 ECT sensor
2 Seal plate
8 Water outlet pipe
3 Camshaft cap
(See 01-10A-7 Camshaft Cap Disassembly Note.) 9 Blind cover
4 Camshaft 10 Cylinder head
(See 01-10A-7 Camshaft Disassembly Note.) (See 01-1 OA-7 Cylinder Head Disassembly Note.)
11 Cylinder head gasket
01-10A-6
MECHANICAL [WL-3]
Camshaft Pulley Disassembly Note
Caution
• Do not move the camshaft from this position because it can cause the valve and piston to contact mI
each other and damage them. ..
1. Hold the camshaft by using a wrench on the cast

hexagon.
DBG110AEB015
Camshaft Cap Disassembly Note
Caution
• Removing the camshaft cap under load can break the camshaft. When removing the camshaft cap,
loosen the locknut and the adjust screw to prevent the camshaft from pressing down the rocker
arm.
Note
• Mark the camshaft cap so that they can be reinstalled in the position from which they were removed.
1. Loosen the camshaft cap bolts in three or four

steps in the order shown in the figure.
ENGINE
FRONT
DBG110AEB025
Camshaft Disassembly Note

1. Before removing the camshaft, inspect the camshaft oil clearance. (See 01-1 OA-21 CAMSHAFT OIL
CLEARANCE INSPECTION [WL-3].)
Cylinder Head Disassembly Note

1. Remove bolts A.
2. Loosen the cylinder head bolts in two or three
DBG110AEB016
01-10A-7
MECHANICAL [WL-3]
CYLINDER HEAD DISASSEMBLY (II) [WL-3]
DCF011002000W05
DBG110AEBR24
1 Pivot 5 Lower valve spring seat

2 Valve keeper 6 Valve
(See 01-10A-8 Valve Keeper Disassembly Note.) 7 Valve seal
3 Upper valve spring seat (See 01-10A-9 Valve Seal Disassembly Note.)
4 Valve spring
Valve Keeper Disassembly Note

1. Remove the valve keeper using the SST. ~. I. • I , :
I'
DBG110AEB026
01-10A-8
MECHANICAL [WL-3]
Valve Seal Disassembly Note
1. Remove the valve seal using the SST.
VALVE GUIDE
DBG110AEB104
CYLINDER BLOCK DISASSEMBLY (I) [WL-3]

DCF011002000W06
DBG110AEB033
1 Oil drain plug I -3 IOil strainer

2 Oil pan
(See 01-10A-10 Oil Pan Disassembly Note.)
01-10A-9
MECHANICAL [WL-3]
Oil Pan Disassembly Note
1. Remove the oil pan using a separator tool.
DBG110AEB035
CYLINDER BLOCK DISASSEMBLY (II) [WL-3]

DCF011002000W07
17
DBG110AEBR40
1 Crankshaft pulley 4 Oil pump

(See 01-10A-11 Crankshaft Pulley Disassembly 5 Fuel injection pump gear
Note.) (See 01-10A-12 Fuel Injection Pump Gear
2 Fuel injection pump pulley Disassembly Note.)
(See 01-10A-11 Fuel Injection Pump Pulley 6 Timing gear
Disassembly Note.) 7 Fuel injection pump
3 Timing gear cover
(See 01-10A-12 Timing Gear Cover Disassembly
Note.)
01-1 OA-1 0
MECHANICAL [WL-3]
8 Timing gear case 12 Oil pump cover

(See 01-10A-14 Timing Gear Case Disassembly 13 Driven gear
Note.)
14 Plug
9 Flywheel
(See 01-10A-14 Flywheel Disassembly Note.) 15 Plunger spring
16 Control plunger
10 End plate
17 Oil pump body
11 Rear cover
(See 01-10A-14 Rear Cover Disassembly Note.)
Crankshaft Pulley Disassembly Note

1. Remove the crankshaft pulley using the SST.
Caution
• The CKP sensor plate is a very important
part for engine operation control; any
deformation of the plate may disable the
operation control.
When disassembling/assembling the
crankshaft pulley, be very careful not to
deform the plate by interference with
other parts or improper handling.
DBG110AEB042
PLATE
DBG110AWB021
Fuel Injection Pump Pulley Disassembly Note

1. Remove the fuel injection pump pulley using the
SST.
DBG110AEB043
01-10A-11
MECHANICAL [WL-3]
Timing Gear Cover Disassembly Note
1. Remove the timing gear cover using a separator
tool.
DBG110AEB044
2. Remove the oil seal using a screwdriver protected
with a rag.
Fuel Injection Pump Gear Disassembly Note

1. Set the No.1 cylinder to TOC of compression.
2. Rotate the flywheel ring gear from TOC to BTDC30°
approximately 30° BTOC (about 13 teeth on the
gear).
DBG110AEB046
3. Verify that the end-gap (V groove) of the timing

gear case and the chip cut gear of the fuel GEAR CASE (V GROOVE)
injection pump gear are aligned.
Note FUEL INJECTION

• If the chip cut gear is hard to find, move the PUMP GEAR
o
fuel injection pump gear on notch back and
forth, then check the chip cut gear.
FUEL INJECTION CHIP CUT GEAR

PUMP GEAR
(HELICAL GEAR)
ABOUT3.0mm
{O.12 in}
DBG110AEBRR8
01-10A-12
MECHANICAL [WL-3]
4. Fix the scissors gear to the fuel injection pump gear using a lock bolt (M8x1.25; length under the bolt head is
approximately 14 mm {O.55 in}).
Warning
• When removing the fuel injection pump gear, be sure to secure the scissors gear to the fuel
injection pump gear using a lock bolt (M8x1.25; length under the bolt head is approximately 14 mm
{O.55 in}). Otherwise, the scissors gear will rotate with the spring force, causing personal injury.
Caution
• When removing the fuel injection pump gear, be sure to secure the scissors gear to the fuel
injection pump gear using a look bolt (M8x1.25; length under the bolt head is approximately 14
mm {O.55 in}) to prevent the scissors gear form rotating with the spring force. Otherwise, the
scissors gear will not align with the fuel injection pump gear, and the fuel injection pump gear with
the scissors gear will not engage with the idler gear. '
Note
• The fuel injection pump gear with a scissors
gear has a lock bolt hole.
DBG110AEBR97
5. Hold the crankshaft using the SST and loosen the

gear nut.
01-10A-13
MECHANICAL [WL-3]
6. Remove the fuel injection pump gear using the
SST.
, .
DBG110AEBR48
Timing Gear Case Disassembly Note

1. Remove the timing gear case using the separator
tool.
Flywheel Disassembly Note

1. Remove the flywheel using the SST.
Rear Cover Disassembly Note

with a rag.
RAG
DBG110AEB052
01-10A-14
~
!
MECHANICAL [WL-3]
CYLINDER BLOCK DISASSEMBLY (III) [WL-3]
DCF011002000W08
13
DBG110AEBR67
1 Connecting rod cap 8 Piston

(See 01-10A-15 Connecting Rod Cap Disassembly 9 Connecting rod
Note.)
10 Main bearing cap
2 Lower connecting rod bearing (See 01-10A-16 Main Bearing yap Disassembly
3 Piston, connecting rod Note.)
(See 01-10A-15 Piston, Connecting Rod 11 Lower main bearing, lower thrust bearing
Disassembly Note.)
12 Crankshaft
4 Upper connecting rod bearing (See 01-10A-16 Crankshaft Disassembly Note.)
5 Piston ring 13 Upper main bearing, upper thrust bearing
6 Piston pin clip 14 Oil jet valve, nozzle
7 Piston pin 15 cylinder block
(See 01-10A-16 Piston Pin Disassembly Note.)
Connecting Rod Cap Disassembly Note

1. Before removing the connecting rod cap, inspect the connecting rod side clearance. (See 01-1 OA-27
CONNECTING ROD SIDE CLEARANCE INSPECTION [WL-3].)
Piston, Connecting Rod Disassembly Note

1. Before removing the piston and connecting rod, inspect the connecting rod oil clearance. (See 01-1 OA-27
CONNECTING ROD OIL CLEARANCE INSPECTION/REPAIR [WL-3].)
2. Inspect the oscillation torque. (See 01-1 OA-28 PISTON' AND CONNECTING ROD INSPECTION [WL-3].)
01-10A-15
MECHANICAL [WL-3]
Piston Pin Disassembly Note
1. Remove the piston pin using the SST.
" I II
DBG110AEB06S
Main Bearing Cap Disassembly Note

1. Before removing the main bearing cap, inspect the crankshaft end play. (See 01-1 OA-26 CRANKSHAFT END
PLAY INSPECTION/REPAIR [WL-3].)
2. Loosen the main bearing cap bolts in two or three
Crankshaft Disassembly Note

1. Before removing the crankshaft, inspect the main journal oil clearance. (See 01-1 OA-26 CRANKSHAFT OIL
CLEARANCE INSPECTION/REPAIR [WL-3].)
CYLINDER HEAD INSPECTION/REPAIR [WL-3]

DCF011 01 01 OOWOl
1. Inspect the cylinder head surface for cracks. Replace the cylinder head if necessary.
2. Inspect for the following and repair or replace.
(1) Sunken valve seats
(2) Excessive camshaft oil clearance and end play
3. Measure the cylinder head for distortion in the
seven directions as shown in the figure. Y
Maximum cylinder head distortion

X distortion: 0.02 mm {O.OOOS in}
Y distortion: 0.05 mm {0.0020 in}
DBG110AEB11E
01-10A-16
MECHANICAL [WL-3]
4. Measure the receded or projected amount of
combustion chamber insert from the cylinder
head surface.
• If it exceeds the maximum specification,
replace the cylinder head.
Maximum combustion chamber recession

0.02 mm {0.0008 in}
Maximum combustion chamber projection COMBUSTION CHAMBER

0.005 mm {0.0002 in} INSERT
DBG110AEB074
5. Inspect the combustion chamber insert crack.

• If it exceeds the limit specification, replace the
cylinder head.
Combustion chamber crack

Limit: 10mm {0.39 in}
DBG110AEB075
6. Measure the manifold contact surface distortion

as shown in the figure.
• If the distortion exceeds the maximum
specification, grind the surface or replace the
cylinder head.
Maximum manifold contact surface distortion

0.05 mm {0.0020 in}
Maximum manifold contact surface grinding

0.15 mm {0.0059 in}
DBG110AEB076
VALVE INSPECTION [WL-3]

DCF011012111W01
1. Measure the valve head margin thickness of each
valve.
-I r-
r-----L.1
• If it exceeds the standard specification, THICKNESS
replace the valve:
Standard valve margin thickness 1

IN: 1.5 mm {0.059 in}
EX: 0.75 mm {0.030 in}
2. Measure the length of each valve. Replace the LENGTH

valve if necessary.
• If it is less than the minimum specification,
B3E0110ER68
replace the valve.
Standard valve length

IN: 111.6-112.1 mm {4.394-4.413 in}
EX: 111.5-112.0 mm {4.390-4.409 in}
Minimum valve length

IN: 111.35 mm {4.384 in}
EX: 111.25 mm {4.380 in}
01-10A-17
MECHANICAL [WL-3]
3. Measure the stem diameter of each valve in the X
and Y directions at the three points (A, B, and C)
shown in the figure.
replace the valve.
Standard valve stem diameter

IN: 6.970-6.985 mm {0.2745-0.2749 in}
EX: 6.965-6.980 mm {0.2743-0.2748 in}
Minimum valve stem diameter

IN: 6.920 mm {0.2724 in}
DBG110AEB106
EX: 6.915 mm {0.2722 in}
VALVE GUIDE INSPECTION [WL-3]

DCF011 01 0280W01
1. Measure the inner diameter of each valve guide in
the X and Y directions at the three pOints (A, B,
and C) shown in the figure.
• If it is not within the specification, replace the
valve guide. A
Standard valve guide inner diameter

7.025-7.045 mm {0.2766-0.2773 in} B
DBG110AEB108
2. Measure the protrusion height (dimension A) of

each valve guide without lower valve spring seat.
valve guide.
Standard valve guide height @-'----L.......JI

14.0-14.5 mm {0.552-0.570 in}
DBG110AEB077
01-10A-18
MECHANICAL [WL-3]
VALVE GUIDE REPLACEMENT [WL-3]
DCF011 01 0280W02
Valve Guide Removal
1. Remove the valve guide from the combustion
chamber side using the SST.
GUIDE
DBG110AEB107
Valve Guide Installation

1. Assemble the SSTs so that depth L is as
specified.
Depth L
14.0-14.5 mm {0.552-0.570 in}
DBG110AEB110
2. Tap the valve guide in from the side opposite the

combustion chamber until the SST contacts the
cylinder head.
3. Verify that the valve guide projection height is
within the specification.
, Standard valve guide height

14.0-14.5 mm {0.552-0.570 in}
VALVE GUIDE
B3E0110E072
VALVE SEAT INSPECTION/REPAIR [WL-3]

DCF011 01 01 02W01
1. Measure the seat contact width.
• If it is not within the specification, resurface
the valve seat using the 45° valve seat cutter.
Standard valve seat contact width

IN: 1.6-2.2 mm {0.063-0.086 in} SEAT CONTACT
WIDTH
EX: 1.7-2.3 mm {0.067-0.090 in} I
.\
DBG110AEB109
01-10A-19
MECHANICAL [WL-3]
2. Verify that the valve seating position is at the
center of the valve face.
• If the seating position is too high, correct the IN EX
valve seat using a 60° cutter, and then a 45°
cutter.
• If the seating position is too low, correct the
valve seat using a 37° (IN) or 30° (EX) cutter,
and a 45° cutter.
Valve seat angle

IN: 45°
EX: 45°
DBG110AEBR75
3. Measure the receded amount from the cylinder

head surface.
replace the cylinder head.
Standard valve recession

IN: 0.61-1.09 mm {0.025-0.042 in}
EX: 0.71-1.19 mm {0.028-0.046 in}
Maximum valve recession

IN: 1.50 mm {0.059 in}
EX: 1.60 mm {0.063 in}
DBG110AEB112
VALVE SPRING INSPECTION [WL-3]

DCF011012125W01
1. Apply a pressing force to the pressure spring and
check the spring height.
valve spring.
Valve spring installation pressing force

238-269 N {25-27 kgf, 54-60 Ibf}
Valve spring installation height

35.5 mm {1.40 in}
DBG0110AEB11
2. Measure the amount the valve spring is out-of-

square.
replace the valve spring.
Maximum valve spring out-of-square

2.0° (1.70mm {0.067 in})
DBG110AEB079
01-10A-20
MECHANICAL [WL-3]
CAMSHAFT INSPECTION [WL-3]
DCF011012420W01
1. Set the No.1 and No.5 journals on V-blocks.
Measure the camshaft runout.
replace the camshaft.
Maximum camshaft runout

0.03 mm {0.0012 in}
DBG110AEB114
2. Measure the cam lobe height at the two points as

.. ..
D o=r
Standard cam lobe height

IN: 42.400-42.500 mm {1.6692-1.6732 in}
EX: 42.395-42.495 mm {1.6691-1.6730 in}
t t
Minimum cam lobe height
IN: 42.050 mm {1.6555 in}
EX: 42.045 mm {1.6711 in}
DBG110AEB080
3. Measure the journal diameters in the X and Y

directions at the two pOints (A and 8) as shown in
the figure.
Standard cam journal diameter

No.1, No.5: 25.940-25.965 mm {1.0213-
1.0222 in}
No.2-No.4: 25.910-25.935 mm {1.0201-
1.0210 in}
DBG110AEB081
Minimum cam journal diameter
No.1, No.5: 25.890 mm {1.0193 in}
No.2-No.4: 25.860 mm {1.0181 in}
CAMSHAFT OIL CLEARANCE INSPECTION [WL-3]

DCF011012420W02
1. Position a plastigage on top of the journals in the axial direction.
2. Install the camshaft cap. (See 01-1 OA-49 Camshaft Cap Assembly Note.)
3. Remove the camshaft cap. (See 01-10A-7 Camshaft Cap Disassembly Note.)
4. Measure the oil clearance.
• If it exceeds the maximum specification, replace the camshaft.
r-----------------------------------~
Standard camshaft clearance

No.1, 5: 0.035-0.081 mm {0.0014-0.0031
in}
No.2-4: 0.065-0.111 mm {0.0026-0.0043
in}
Maximum camshaft clearance

No.1, 5: 0.12 mm {0.0047 in}
No.2-4: 0.15 mm {0.0059 in}
DBG110AEB082
01-10A-21
MECHANICAL [WL-3]
CAMSHAFT END PLAY INSPECTION [WL-3]
DCF011012420W03
1. Install the camshaft cap. (See 01-10A-49 Camshaft Cap Assembly Note.)
2. Measure the camshaft end play.
• If it exceeds the maximum specification, replace the cylinder head or camshaft.
~------------------------------------.
Standard camshaft end play

0.030-0.160 mm {0.0012-0.0062 in}
Maximum camshaft end play

0.20 mm {0.0079 in}
3. Remove the camshaft cap. (See 01-1 OA-7

Camshaft Cap Disassembly Note.)
DBG110AEB083
CYLINDER BLOCK INSPECTION/REPAIR [WL-3]

DCF011 01 0300W01
1. Measure the distortion of the cylinder block top
surface in the seven directions as shown in the y
figure.
• If the distortion exceeds the maximum
specification, replace the cylinder head.
Maximum cylinder block distortion

X direction: 0.02 mm {0.0008 in}
Y direction: 0.05 mm {0.0020 in}
DBG110AEB115
2. Measure the cylinder bore using the cylinder

gauge. Measurement positions are in the X and Y
directions at 83 mm {3.27 in} below the top
surface of the cylinder.
• If the cylinder bore exceeds the wear limit,
replace the cylinder block or rebore the
cylinder and install the oversized pistons so
that the specified piston-to-cylinder clearance
is obtained.
Note
• Base the boring diameter on the diameter of
ADA2224ER91
an oversized piston. All cylinders must be
the same diameter.
Cylinder bore size

Standard: 93.000-93.022 mm {3.6615-3.6622 in}
0.25 {0.01} oversize: 93.250-93.272 mm {3.6713-3.6721 in}
0.50 {0.02} oversize: 93.500-93.522 mm {3.6811-3.6819 in}
Cylinder bore wear limit

0.15 mm {0.0059 in}
01-10A-22
MECHANICAL [WL-3]
OIL JET VALVE, NOZZLE INSPECTION [WL-3]
DCF011 01 0730W01
1. Apply compressed air to oil jet valve A and verify
"a that air passes through oil jet valve B.
'. • If it is not within the specification, replace the
oil jet.
Oil jet air pressure

137.6-196.4 kPa {1.5-2.0 kgf/cm 2 , 20-28
psi}
2. Check the oil jet nozzle for clogs. Replace the

nozzle if necessary.
DBGll0AEB085
PISTON INSPECTION [WL-3]

DCF011011010W01
1. Measure the outer diameter of each piston at right
angle (90°) to the piston pin, 17 mm {0.67 in}
from the lower end of the piston.
piston.
Piston diameter
Standard: 92.951-92.977 mm {3.6595-
3.6605 in}
17mm
0.25 {0.0098} oversize: 93.186-93.212 mm {O.67 in}
{3.6688-3.6697 in}
0.50 {0.02} oversize: 93.436-93.462 mm
DBG110AEBR74
{3.6786-3.6795 in}
_ PISTON CLEARANCE INSPECTION/REPAIR [WL-3]

DCF011011010W02
1. Measure the piston-to-cylinder clearance.
• If it exceeds the maximum specification, replace the piston or rebore the cylinders to fit the oversized
piston.
, Standard piston clearance

0.055-0.073 mm {0.0022-0.0028 in}
Maximum piston clearance

0.15 mm {0.0059 in}
2. If the piston is replaced, the piston rings must also be replaced.
PISTON RING CLEARANCE INSPECTION [WL-3]

DCF011011010W03
1. Measure the piston ring-to-ring land clearance
around the entire circumference. .
replace the piston and piston ring.
Standard piston ring clearance

Top: 0.06-0.10 mm {0.0024-0.0039 in}
Second: 0.04-0.08 mm {0.0016-0.0031 in}
Oil: 0.03-0.07 mm {0.0012-0.0027 in}
Maximum piston ring clearance

0.15 mm {0.0059 in}
DBGll0AEB116
2. Insert the piston ring into the cylinder by hand and

use the piston to push it to the bottom of the ring travel:
01-10A-23
MECHANICAL [WL-3]
3. Measure each piston ring end gap with a feeler
gauge.
replace the piston ring.
Standard piston ring end gap

Top: 0.22-0.32 mm {0.0087-0.0125 in}
Second: 0.32-0.47 mm {0.0126-0.0185 in} PISTON
Oil: 0.22-0.37 mm {0.0087-0.0145 in} RING
Maximum piston ring end gap

1.0 mm {0.039 in}
DBG110AEB087
PISTON PIN CLEARANCE INSPECTION [WL-3]

DCF011011010W04
1. Measure each piston pin bore diameter in the X
and Y directions at the four points (A, B, C, and D)
Standard piston pin bore diameter

31.997-32.007 mm {1.2598-1.2601 in}
~
v
DBG110AEB088
2. Measure each connecting rod small end inner

diameter in the X and Y directions as shown in the x
figure.
Standard connecting rod small end inner

diameter
32.012-32.033 mm {1.2604-1.2611 in}
DBG110AEB117
3. Measure each piston pin diameter in the X and Y x

directions at the four pOints (A, B, C and D) as
J
Standard piston pin diameter

-©-v
31.994-32.000 mm {1.25961-1.25984 in} t
4. Calculate the piston pin-to-piston pin bore
clearance.
piston or the piston pin.
DBG110AEB118
Standard piston pin-to-piston pin bore
clearance
-0.003-0.013 mm {-0.00011-0.00051 in}
5. Calculate the connecting rod small end-to-piston pin clearance.

• If it is not within the specification, replace the connecting rod or the piston pin.
Standard connecting rod small end-to-piston pin clearance

0.012-0.039 mm {0.00048-0.00153 in}
01-10A-24
MECHANICAL [WL-3]
CRANKSHAFT INSPECTION [WL-3]
DCF011011301W01
1. Measure the crankshaft runout.
replace the crankshaft.
Maximum crankshaft run out

0.05 mm {0.0020 in}
DBG110AEB089
2. Measure the main journal or crank pin diameter in

the X and Y directions at the two points (A and 8) A B
• If it is not within the specification or if it x
exceeds the maximum off-round, grind the
main journal or crank pin with an undersized
bearing. 1+---+----1 y
Main journal diameter

Standard
No.1, 2, 4, 5: 66.937-66.955 mm {2.6354-
2.6360 in}
DBG110AEB090
No.3: 66.920-66.938 mm {2.6347-2.6353
in}
0.25 {0.01} undersize
No.1, 2, 4, 5: 66.687-66.705 mm {2.6255~2.6261 in}
No.3: 66.670--':66.688 mm {2.6248-2.6255 in}
No.1, 2, 4, 5: 66.437-66.455 mm {2.6157-2.6163 in}
No.3: 66.420-66.438 mm {2.6150-2.6156 in}
No.1, 2, 4, 5: 66.187-66.205 mm {2.6058-2.6064 in}
No.3: 66.170-66.188 mm {2.6052-2.6058 in}
Main journal wear limit

0.05 mm {0.0020 in}
Main journal out-of-round

0.03 mm {0.0012 in}
Crank pin diameter

Standard: 54.940-54.955 mm {2.1630-2.1635 in}
0.25 {0.01} undersize: 54.690-54.705 mm {2.1532-2.1537 in}
0.50 {0.02} undersize: 54.440-54.455 mm {2.1434-2.1438 in}
0.75 {0.03} undersize: 54.190-54.205 mm {2.1335-2.134 in}
Crank pin wear limit

0.05 mm {0.0020 in}
Crank pin out-of-round

0.03 mm {0.0012 in}
\I
01-10A-25
MECHANICAL [WL-3]
CRANKSHAFT OIL CLEARANCE INSPECTION/REPAIR [WL-3]
DCF011011301W02
2. Install the main bearing cap. (See 01-10A-34 Main Bearing Cap Assembly Note.) ~'
3. Remove the main bearing cap. (See 01-1 OA-16 Main Bearing Cap Disassembly Note.) ''''i1
4. Measure the main journal oil clearance.
• If the clearance exceeds the maximum specification, replace the main bearing or grind the main journal and
install the undersize bearings so that the specified oil clearance is obtained.
Standard main journal clearance

No.1, 2, 4, 5: 0.027-0.046 mm {0.0011-0.0018 in}
No.3: 0.044-0.063 mm {0.0018-0.0025 in}
Maximum main journal clearance

0.08 mm {0.0031 in}
Main bearing thickness

Standard: 2.006-2.021 mm {0.0790-0.0795 in}
0.25 {0.01} undersize: 2.124-2.134 mm {0.0837-0.0840 in}
0.50 {0.02} undersize: 2.249-2.259 mm {0.0886-0.0889 in}
0.75 {0.03} undersize: 2.374-2.384 mm {0.0935-0.0938 in}
CRANKSHAFT END PLAY INSPECTION/REPAIR [WL-3]

DCF011011301W03
1. Install the main bearing cap. (See 01-1 OA-34 Main Bearing Cap Assembly Note.)
2. Measure the crankshaft end play. ,----------------------,
• If the end play exceeds the maximum
specification, replace the thrust bearing or
grind the crankshaft and install an oversized
bearing so that the specified end play is
obtained.
Standard crankshaft end play

0.040-0.282 mm {0.0016-0.0111 in}
Maximum crankshaft end play

0.3 mm {0.012 in}
DBG110AEB120
Thrust bearing thickness

Standard: 2.454-2.506 mm {0.0967-0.0986 in}
0.35 {0.014} oversize: 2.629-2.681 mm {0.1 036-0.1 055 in}
3. Remove the main bearing cap. (See 01-10A-16 Main Bearing Cap Disassembly Note.)
CONNECTING ROD INSPECTION [WL-3]

DCF011011211W01
1. Measure each connecting rod for bending and
distortion.
replace the connecting rod.
Maximum connecting rod bending

0.075 mm {0.0030 in} /50 mm {2.0 in}
Maximum connecting rod distortion

0.18 mm {0.0071 in} /50 mm {2.0 in}
Connecting rod center-to-center distance

DBG110AEB119
151.96-152.04 mm {5.9827-5.9858 in}
01-10A-26
MECHANICAL [WL-3]
2. Measure the length of the connecting rod bolt.
replace the connecting rod and connecting
rod cap.
Standard connecting rod bolt length

67.5-68.5 mm {2.66-2.69 in}
Maximum connecting rod bolt length

69 mm {2.7 in}
DBG110AEB092
CONNECTING ROD OIL CLEARANCE INSPECTION/REPAIR [WL-3]

DCF011011211W02
2. Install the connecting rod cap. (See 01-10A-35 Piston, Connecting Rod Assembly Note.)
3. Remove the connecting rod cap.
4. Measure the crankpin oil clearance.
• If the clearance exceeds the maximum,
replace the connecting rod bearing or grind
the crankpin and use undersized bearings so
that the specified clearance is obtained.
Standard connecting rod oil clearance

0.025-0.052 mm {0.0010-0.0020 in}
Maximum connecting rod oil clearance

0.08 mm {0.0031 in}
DBG110AEB121
Connecting rod bearing thickness
)')1 Standard: 1.507-1.516 mm {0.0594-0.0596
in}
0.25 {0.01} undersize: 1.624-1.634 mm {0.0640-0.0643 in}
0.50 {0.02} undersize: 1.749-1.759 mm {0.0689-0.0692 in}
0.75 {0.03} undersize: 1.874-1.884 mm {0.0738-0.0741 in}
CONNECTING ROD SIDE CLEARANCE INSPECTION [WL-3]

DCF011011211W03
1. Install the connecting rod cap. (See 01-10A-35 Piston, Connecting Rod Assembly Note.)
2. Measure the connecting rod large end side
clearance.
replace the connecting rod and connecting
rod cap.
Standard connecting rod side clearance

0.110-0.262 mm {0.0044-0.0103 in}
Maximum connecting rod side clearance

0.35 mm {0.014 in}
DBG110AEB122
01-10A-27
MECHANICAL [WL-3]
PISTON AND CONNECTING ROD INSPECTION [WL-3]
DCF011011010W05
1. Check the oscillation torque as shown in the
figure. If the large end does not drop by its own
weight, replace the piston or the piston pin.
DBG110AEB093
BOLT INSPECTION [WL-3]

DCF011010135W01
1. Measure the length of each bolt.
replace the bolt.
Cylinder head bolt length

Bolt head mark W
~ (( J);));))))))))))))
Standard length: 101.2-101.8 mm
4.007 in}
Maximum length: 102.5 mm {4.035
{3.985-
in}
I. LENGTH
.1
Bolt head mark N
Standard length: 113.2-113.8 mm {4.457-
4.480 in}
DBG110AEB097
Maximum length: 114.5 mm {4.508 in}
Main bearing cap bolt length

Standard length: 84.7-85.3 mm {3.34-3.35 in}
TENSIONER SPRING INSPECTION [WL-3]

DCF011012711W01
1. Measure the free length of the tensioner spring.
• If it exceeds the standard specification,
replace the tensioner spring.
Standard tensioner spring length

63.0 mm {2.48 in}
FREE LENGTH
DBG110AEB098
01-10A-28
MECHANICAL [WL-3]
VALVE CLEARANCE INSPECTION [WL-3]
DCF011012111W02
1. Turn the crankshaft and align the timing mark so that the piston of the No.1 or No.4 cylinder is at TOG of
compression.
2. Measure valve clearances A with the No.1
A A A
cylinder at TOG of compression, and those of B
with the No.4 cylinder at TOG of compression.
• If it is not within the specification, adjust and
recheck the valve clearance.
ENGINE
FRONT
B B B
DBGll0AEB099
Valve clearance (engine cold)

IN: 0.05-0.15 mm {0.0020-0.0059 in} FEELER GAUGE
EX: 0.15-0.25 mm {0.0060-0.0098 in}
LOCKNUT
3. Turn the crankshaft one full turn and measure the
remaining valve clearances. Adjust if necessary.
DBG110AEB100
VALVE CLEARANCE ADJUSTMENT [WL-3]
;1
DCF011012111W03
Caution
• Loosening the locknut and the adjust screw while the cam lobe is not pressing down the rocker
arm will damage the claw of the rocker arm. When loosening the locknut and the adjust screw,
rotate the crankshaft clockwise and be sure that the cam lobe presses down the rocker arm firmly
1. Remove the cylinder head cover.

2. Turn the crankshaft and align the timing mark so CAM LOBE
that the piston of the No.1 or No.4 cylinders is at
TOG of the compression.
LOCKNUT
CLAW -t--;::;.:;:t:j,.......,
DBG110AWB002
01-10A-29
MECHANICAL [WL-3]
3. Adjust the valve clearances A with the No.1
cylinder at TOG of compression, and those of B A A A
with the No.4 cylinder at TOG of compression.
ENGINE
FRONT
B B B
DBGll0AWBOOl
Valve clearance
IN: 0.05 - 0.15 mm {0.0020 - 0.0059 in}
[Engine cold]
0.15 mm {0.0059 in}
[Engine hot (reference)]
EX: 0.15 -0.25 mm {O.OOSO - 0.0098 in}
[Engine cold]
0.25 mm {0.0098 in}
[Engine hot (reference)]
Tightening torque (locknut)

DBGll0AWB003
1S-20 N·m {1.7-2.0 kgf·m, 12-14 ft·lbf}
4. Turn the crankshaft one full turn and adjust the remaining valve clearances.
INJECTION TIMING ADJUSTMENT [WL-3]

DCF011002000W09
Caution
• Excessive tension on the timing belt may cause damage to the timing belt and camshaft. If the bolt
and nuts of the fuel injection pump are temporarily loosened, re-tension the timing belt.
1. Loosen the bolts and nuts of the fuel injection

pump and bracket.
DBGll0AEBR76
2. Rotate the crankshaft clockwise and align the INDICATOR PIN

crankshaft pulley TOG mark (yellow mark) with
the indicator pin. TDC (YELLOW MARK)
3. Remove the hydraulic head plug of the fuel
injection pump.
01-10A-30
MECHANICAL [WL-3]
-4. Insert the SST into the hydraulic head plug hole
and install it so that the dial gauge indicates
approx. 2 mm {O.OS in}.
5. Rotate the crankshaft counterclockwise and find

the place where the dial gauge needle does not
move near approx. 30° BTDC .. (SST installation
bolt hole of crankshaft pulley and indicator pin
align at approx. 30° BTDC)
6. Set the dial gauge to 0 mm {O in}.
7. Rotate the crankshaft clockwise and read the dial

gauge when the 10° ATDC mark (white mark) of
the crankshaft pulley and the indicator pin align.
8. Adjust the dia1auge within the specification.
Fuel injection pump plunger adjustment value

0.95-1.05 mm {0.03S-0.041 in}
9. Tighten the fuel injection pump in the order shown

in the figure.
10. Remove the SST and install the hydraulic head
plug through a new gasket.
11. Re-tension the timing belt.
DBGll0AEBR77
01-10A-31
MECHANICAL [WL-3]
GEAR CLEARANCE INSPECTION [WL-3]
DCF011019220W01
1. Measure the following clearance.
• If it exceeds the maximum specification, replace the gear and/or pump body.
r-----------------------------------~
Standard oil pump tip clearance

0.10-0.19 mm {0.0040-0.0074 in}
Maximum oil pump tip clearance

0.20 mm {0.0079 in}
DBG110AEB101
Standard oil pump side clearance

0.04-0.09 mm {0.0016-0.0035 in}
Maximum oil pump side clearance

0.15 mm {0.0059 in}
DBG110AEB102
PLUNGER SPRING INSPECTION [WL-3]

DCF011014116W01
1. Measure the free length of plunger spring .
replace the plunger spring.
Standard plunger spring length

43.8 mm {1.72 in}
DBG110AEB103
01-10A-32
MECHANICAL [WL-3]
CYLINDER BLOCK ASSEMBLY (I) [WL-3]
DCF011 002000W1 0
1. Assemble in the order indicated in the table.
12-18 N·m {123-183 kgf·cm, 107-159 in·lbf}

26.5-31.5
{2.8-3.2, 2D-23} + 82.5°-97.5°
+ 90°-105°
N·m {kgf.m, ft·lbf}
DBG110AEBR68
1 Cylinder block 9 Piston pin

2 Oil jet valve, nozzle (See 01-10A-34 Piston, Connecting Rod, Piston
Pin Assembly Note.)
3 Upper main bearing, upper thrust bearing
10 Piston pin clip
4 Crankshaft
11 Piston ring
5 Lower main bearing, lower thrust bearing (See 01-10A-35 Piston Ring Assembly Note.)
6 Main bearing cap 12 Upper connecting rod bearing
(See 01-10A-34 Main Bearing Cap Assembly
Note.) 13 Piston, connecting rod
(See 01-10A-35 Piston, Connecting Rod Assembly
7 Connecting rod . . Note.)
(See 01-1 OA-34 Piston, Connecting Rod, Piston
Pin Assembly Note.) 14 Lower connecting rod bearing
8 Piston 15 Connecting rod cap
(See 01-10A-34 Piston, Connecting Rod, Piston
Pin Assembly Note.)
01-10A-33
MECHANICAL [WL-3]
Main Bearing Cap Assembly Note
1. Apply clean engine oil to the bolt threads and seat faces of the lower cylinder block bolts.
2., Tighten. the b~lts in two or three steps in the order 8 4 1
shown In the figure.
Tightening procedure
(1) 14.5-34.5 N·m {1.5-3.5 kgf·m, 11-25
ft·lbf}
(2) 74.0-82.0 N·m {7.6-8.3 kgf·m, 55-60
ft.lbf}
(3) Loosen all the bolts (until bolts are
torque-free).
(4) 14.5-34.5 N·m {1.5-3.5 kgf·m, 11-25
ft·lbf}
DBG110AEB071
(5) 42.5-45.5 N·m {4.4-4.6 kgf·m, 32-33
ft·lbf}
3. Put a paint mark on each bolt head.

4. Using the marks as a reference, tighten the bolts
by turning each 90°-105° as in Step 2.
PAINT MARK
DBG110AEBR72
Piston, Connecting Rod, Piston Pin Assembly Note

1. Install one piston pin clip.
2. Assemble the piston and connecting rod in the direction indicated in the figure.
3. Apply clean engine oil to the piston pin.
4. Install the piston pin until the pin contacts the clip
as shown. If the pin cannot be installed easily, FMARK
heat the piston.
PROJECTION FOR ALIGNING

CONNECTIOG ROD BEARING
DPE110ZE1R18
01-10A-34
MECHANICAL [WL-3]
piston Ring Assembly Note
1. Install the oil ring.
2. Install the second ring with tapered face side upward.
_ 3. Install the top ring with tapered face side upward.
SECTION OF TOP RING
==( )
SECTION OF SECOND RING
DBG110AEBR96
Piston, Connecting Rod Assembly Note

1. Insert the piston and connecting rod assembly
into the cylinder with the F mark facing the front of
the engine.
2. Tighten the connecting rod cap nuts in two or
three steps. FMARK
Tightening torque
26.5-31.5 N·m {2.8-3.2 kgf.m, 20-23 ft.lbf}
3. Put a paint mark on each nut.
DBG110AEBR95
4. Using the marks as a reference, tighten the nuts

by turning each 82.5°-97.5°
PAINT MARK
DBG110AEBR73
01-10A-35
MECHANICAL [WL-3]
CYLINDER BLOCK ASSEMBLY (II) [WL-3]
DCF011002000W11
~~~~~~==~------------------It
lS.6-25.5 {1.9-2.6, 14-1S}
7.S-10.S N·m
{Sl-110 kgf·cm,
70-95 in·lbf} iii
J~A
7.S-9.S N·m {S0-99 kgf·cm,
70-S6 in·lbf}
7.S-10.S N·m {SO-ll a kgf.cm,

70-95 in·lbf}
N·m {kgf·m, ft·lbf}
DBG110AEBR41
1 Oil pump body 11 Fuel injection pump

2 Control plunger 12 Timing gear
3 Plunger spring (See 01-10A-38 Timing Gear, Fuel Injection Pump
Gear Assembly Note.)
4 Plug
13 Fuel injection pump gear
5 Driven gear
(See 01-10A-38 Timing Gear, Fuel Injection Pump
6 Oil pump cover Gear Assembly Note.)
(See 01-10A-37 Oil Pump Cover Assembly Note.) Oil pump
14
7 Rear cover, end plate 15 Timing gear cover
(See 01-10A-37 Rear Cover, End Plate Assembly (See 01-10A-40 Timing Gear Cover Assembly
Note.) Note.)
8 End plate 16 Fuel injection pump pulley
(See 01-10A-37 Rear Cover, End Plate Assembly (See 01-10A-41 Fuel Injection Pump Pulley
Note.) Assembly Note.)
9 Flywheel Crankshaft pulley
17
(See 01-10A-38 Flywheel Assembly Note.) (See 01-10A-41 Crankshaft Pulley Assembly
10 Timing gear case Note.)
(See 01-1 OA-38 Timing Gear Case Assembly
Note.)
01-10A-36
MECHANICAL [WL-3]
-Oil Pump Cover Assembly Note
1. Tighten the bolts in two or three steps in the order
Rear Cover, End Plate Assembly Note

1. Apply soapy water along the perimeter of the new oil seal.
2. Push the oil seal slightly in by hand.
3. Tap the oil seal in evenly by using the SST and a
hammer.
4. To ensure that the oil seal is installed correctly,
measure the distance between the end of the rear
cover and the face of the oil seal.
Rear oil seal press-in amount

0-0.5 mm {O-O.01 in}
f...Q:-O.5 mm {O-O.01 in}
t~ REAR OIL SEAL
I
DBGll0BEB059
5. ~pply fSilicone sealant to the rear cover as shown

In the igure.
Thickness
~2.0-3.0 mm {O.079-0.118 in}
DBGll0AEBR55
6. Apply silicone sealant to the rear cover as shown

in the figure.
Thickness
~2.0-3.0 mm {O.079-0.118 in}
7. Install the end plate.
DBGll0AEBR94
01-10A-37
MECHANICAL [WL-3]
Flywheel Assembly Note
1. Hold the crankshaft using the SST.
2. Tighten the bolts in the order shown in the figure.
DBGll0AEB056
Timing Gear Case Assembly Note

1. Install the new O-ring. .
2. Apply silicone sealant to the timing gear case as
shown in the figure. Do not apply sealant to the 0-
ring.
Thickness
4>2.0-3.0 mm {0.079-0.118 in}
3. Tighten the bolts in two or three steps in the order .-----------------~

Timing Gear, Fuel Injection Pump Gear Assembly Note

1. Put a paint mark on the chip cut gear of the fuel r------------------~
injection pump gear. PAINT MARK
CHIP CUT
GEAR
DBGll0AEB9R3
01-10A-38
MECHANICAL [WL-3]
2. Put a paint mark on the 11 th and 12th teeth of the CHIP CUT GEAR
helical gear counting clockwise from the chip cut
gear. FUEL
INJECTION
PUMP GEAR
VIEWA
PAINT MARK
DBG110AEBR83
3. Verify that the 11 th and 12th teeth of fuel injection
pump gear (helical gear) and the teeth of the SCISSORS GEAR HELICAL GEAR
~I
scissors gear are aligned, then put a paint mark
on the scissors gear.
~~11
TEETH
~~12TEETH
PAINT MARK
DBG110AEBR82
approximately 30° BTOC (13 teeth on the gear).
DBG110AEBR59
6. Align the timing marks. For the fuel injection pump gear, align the timing mark as shown in the figure (View A).
Note
• The helical gears except for the fuel injection pump gear have a punch mark as the timing mark. The
timing mark of each gear can be aligned easily if the paint mark is made on the punch mark.
TIMING MARK (WHITE PAINT)
FUEL INJECTION
PUMP GEAR
DBG110AEBR60
01-10A-39
MECHANICAL [WL-3]
7. Remove the lock bolt.
DBG110AEBR97
8. Tighten the bolts using the SST.
Timing Gear Cover Assembly Note

3. Tap the oil seal in evenly using the SST and a
hammer. , .
measure the distance between the end of the
timing gear cover and the face of the oil seal.
Front oil seal press-in amount

0-0.4 mm {0-0.01 in}
Fuel injection pump oil seal press-in amount

0-0.4 mm {0-0.01 in}
DBG110BEBR12
5. Apply silicone sealant to the timing gear cover as

Thickness
~2.0-3.0 mm {0.079-0.118 in}
o
o
o o
DBG110AEBR63
01-10A-40
MECHANICAL [WL-3]
Fuel Injection Pump Pulley Assembly Note

1. Install the fuel injection pump pulley using the
SST.
DBG110AEB065
Crankshaft Pulley Assembly Note
Caution
• The CKP sensor plate is a very important
part for engine operation control; any
deformation of the plate may disable the PLATE
operation control.
'When disassembling/assembling the
crankshaft pulley, be very careful not to
deform the plate by interference with
other parts or improper handling.
DBG110AWB021
1. Install the crankshaft pulley using the SST.
• I
DBG110AEB066
01-10A-41
MECHANICAL [WL-3]
CYLINDER BLOCK ASSEMBLY (III) [WL-3]
DCF011002000W12
...----_18.6-25.5 {1.9-2.6, 14-18}
7.8-10.8 N·m
{80-110 kgf.cm,
70-95 in·lbf} N·m {kgf·m, ft·lbf}
DBG110AEBR90
1 Oil pipe 3 Oil pan

(See 01-10A-43 Oil Pipe Assembly Note.) (See 01-10A-43 Oil Pan Assembly Note.)
2 Oil strainer 4 Oil drain plug
01-10A-42
MECHANICAL [WL-3]
Oil Pipe Assembly Note
DBGll0AEBR89
..
Oil Pan Assembly Note
1. Apply silicone sealant to the oil pan as shown in
the figure.
Thickness
~2.0-3.0 mm {O.08-0.118 in}
o 0 0 o o
DBGll0AEBR87
!o'
2. Tighten the oil pan bolts A as shown in the figure.
I
ly@«=E
Caution
• If the bolts are reused, remove the old
sealant from the bolt threads. Tightening
a bolt that has old sealant on it can cause
bolt hole damage.
3. Tighten the remaining oil pan bolts in several

passes. ~ OLD SEALANT
CHUOlllW004
01-10A-43
MECHANICAL [WL-3]
CYLINDER HEAD ASSEMBLY (I) [WL-3]
DCF011002000W13

DBG110AEBR27
1 Valve seal 5 Upper valve spring seat

(See 01-10A-44 Valve Seal Assembly Note.) 6 Valve keeper
2 Valve (See 01-10A-45 Valve Keeper Assembly Note.)
3 Lower valve spring seat 7 Pivot
4 Valve spring
Valve Seal Assembly Note

1. Assemble the SSTs so that depth L is as
specified.
Depth L
15.6 mm {O.614 in}
2. Press the valve seal onto the valve guide by hand.
DPE110ZE1R26
01-10A-44
MECHANICAL [WL-3]
3. Tap the SST using a plastic hammer until its lower
end touches the cylinder head. .
Valve Keeper Assembly Note

1. Install the valve keeper using the SST.
01-10A-45
MECHANICAL [WL-3]
CYLINDER HEAD ASSEMBLY (II) [WL-3]
DCF011002000W14
11.27-14.21 N·m {115-144 kgf·cm,
100-125 in.lbf}r-_ _ _ _ _...J
15.7-23.5 {1.7-2.3, 12-17}
5
6.5-9.0 N·m {67-91 kgf·cm,

58-79in·lbf}
17.6-19.6 {1.8-1.9, 13-14} 11
+ 90°_105°
+ 90°_105°
4
1m
10
11
N·m {kgf·m, tt·lbf}
DBG110AEBR09
1 Cylinder head gasket 7 Rocker arm

(See 01-10A-47 Cylinder Head Gasket Assembly (See 01-10A-49 Rocker Arm Assembly Note.)
Note.) 8 Camshaft
2 Cylinder head 9 Camshaft cap
(See 01-10A-48 Cylinder Head Assembly Note.) (See 01-10A-49 Camshaft Cap Assembly Note.)
3 Blind cover 10 Seal plate
(See 01-10A-48 Blind Cover Assembly Note.) (See 01-10A-50 Seal Plate Assembly Note.)
4 Water outlet pipe 11 Camshaft pulley
5 ECTsensor (See 01-10A-50 Camshaft Pulley Assembly Note.)
6 Water temperature sender unit
(See 01-10A-48 Water Temperature Sender Unit
Assembly Note.)
01-10A-46
MECHANICAL [WL-3]
, .:
'.. •.
cylinder Head Gasket Assembly Note
1. Measure the piston topping of all the cylinders .
~ TOPPING
CYLINDER PISTON
BLOCK
DPE110ZE1R02
2. Choose the gasket according to each measured

piston topping.
Cylinder head gasket select table
Cylinder head gasket
Piston topping (mm {in}) identification mark
0.205-0.325 {0.081-0.127}
IDENTIFICATION MARK
POSITION
0.265-0.385 {0.105-0.151}
J DPE11 OZE1 R01
t
0.325-0.445 {0.128-0.175}
L - - -_ _ _. . . . L . . - - _ - - - '
;
3. Apply silicone sealant to the cylinder block as
15.0 mm
Thic,kness {0.53 in}
~2.0-3.0 mm {O.079-0.118 in} 40.5 mm
{1.59 in} ENGINE
FRONT
48.5 mm
{1.91 in}
9.0mm
{0.35 in}
DBG110AEBR17
01-10A-47
MECHANICAL [WL-3]
Cylinder Head Assembly Note
1. Before installing the cylinder head bolts, inspect their length. (See 01-10A-28 BOLT INSPECTION [WL-3].)
2. Apply clean engine oil to the threads and the seat face of each bolt and install them.
3. Tighten the cylinder head bolts in the order
indicated in the figure in several passes.
Tightening torque
29 N·m {3.0 kgf·m, 2.1 ft·lbf}
4. Retighten the bolts in the order shown in the

figure until all the bolts are tightened to 29 N·m
{3.0 kgf·m, 2.1 ft.lbf}.
DBG110AEB018

6. Using the marks as a reference, tighten the PAINT MARK
cylinder head bolts by turning each 90°-105° in
the order indicated in Step 3.
7. Further tighten each bolt by turning another 90°-
105° in the order indicated in Step 3.
8. Tighten the bolts A. --¢
Tightening torque
17.6-19.6 N·m {1.8-1.9I<:gf·m, 13-14 ft.lbf}
DBG110AEB019
Blind Cover Assembly Note

1. Apply silicone sealant to the blind cover as shown
in the figure.
Thickness
~1.5-2.5 mm {0.059-0.098 in}
DBG110AEBR23
Water Temperature Sender Unit Assembly Note

1. Apply silicone sealant to the thread of the water
temperature sender unit as shown in the figure.
DBG110AEB022
01-10A-48
MECHANICAL [WL-3]
-
Rocker Arm Assembly Note
1. If new rocker arm is used, set dimension A as
"
follows.
3:
"
"
"c,
Dimension A
0.0-4.0 mm {0.0-0.15 in}
DBG110AEB030
Camshaft Cap Assembly Note

1. Apply silicone sealant to the front camshaft cap
mounting surfaces as indicated in the figure.
Avoid getting sealant onto the camshaft journal,
camshaft oil seal surface, and camshaft thrust
surface. ENGINE
FRONT
DBG110AEB031
2. Tighten the camshaft cap bolts gradually in three

or four steps in the order shown in the figure.
I Caution
• Because there is little camshaft thrust
clearance, the camshaft must be held ENGINE
horizontally while it is installed. FRONT
Otherwise, excessive force will be
applied to the thrust area, causing burrs
on the thrust receiving area of the
cylinder head journal. To avoid this, the
following procedure must be observed.
DBG110AEB032
3. Apply soapy water along the perimeter of the new

oil seal.
5. Tap the oil seal lightly into the cylinder head
~
using the SST and a hammer.
cylinder head and the face of the oil seal.
0.5-1.0 mm {0.02-0.03 in}
Camshaft oil seal press-in amount
Ii
0.5-1.0 mm {0.02-0.03 in}
HAMMER
OIL SEAL
DPE110ZE1R41
01-10A-49
MECHANICAL [WL-3]
Seal Plate Assembly Note
1. Tighten the seal plate bolts in the order indicated
in the figure.
DBG110AEB020
Camshaft Pulley Assembly Note

1. Install the camshaft pulley on the camshaft with
the knock pin fitted into the hole at the timing TIMING MARK
mark.
KNOCK PIN
Timing mark
WL
DBG110AEBR85
2. Hold the camshaft using a wrench on the cast hexagon and tighten the pully lock bolt.
Caution
• Do not move the camshaft from this
position because it can cause the valve
and piston to contact each other and
damage them.
DBG110AEB021
01-10A-50
MECHANICAL [WL-3]
TIMING BELT ASSEMBLY [WL-3]
DCF011002000W15
4.9-8.8 N·m {50-90 kgf·cm, 44-78 in·lbf} - - - -_ _~
, 7.8-10.8 N·m {80-110 kgf.cm,

70-95 in·lbf}
18.6-25.5 {1.9-2.6, 14-18}

DBG110AEBR07
Timing belt 4 Timing belt cover

(See 01-10A-52 Timing Belt, Tensioner, Tensioner (See 01-10A-52 Timing Belt Cover Assembly
Spring Assembly Note.) Note.) <'
2 Tensioner, tensioner spring 5 Cylinder head cover

(See 01-1 OA-52 Timing Belt, Tensioner, Tensioner (See 01-10A-52 Cylinder Head Cover Assembly
Spring Assembly Note.) Note.)
3 Pulley plate 6 Vacuum pump
7 Water pump
01-10A-S1
MECHANICAL [WL-3]
Timing Belt, Tensioner, Tensioner Spring Assembly Note
Caution
• Overtensioning of the timing belt can cause breakage of the belt and the camshaft.
1. Align the timing marks as shown in the figure. TENSIONER

2. Verify that the fuel injection pump attaching bolts LOCK BOLT CAMSHAFT
and nuts are tightened to the specified torque. PULLEY
This must be done to prevent overtensioning of
the timing belt after it has been installed.
3. Install the timing belt.
4. Install the tensioner, tensioner spring, and the TENSIONER
lock bolt. SPRING
5. Tighten the tensioner lock bolt. TENSIONER
6. Turn the crankshaft clockwise twice, and align the
timing marks. If they are not aligned, remove the - / - - - - FUEL INJECTION PUMP
PULLEY
timing belt and repeat from Step 1.
DBG110AEBR11
7. Loosen the tensioner lock bolt to apply tension to
the belt. Do not apply tension other than that of
the tensioner spring.
8. Tighten the tensioner lock bolt. Be sure the tensioner does not move together with the bolt rotation.
Timing Belt Cover Assembly Note
1. Tighten the timing belt cover bolts in the order
shown in the figure. .
®
DBG110AEB012
Cylinder Head Cover Assembly Note

1. Before installing the cylinder head cover, inspect the valve clearance. (See 01-1 OA-29 VALVE CLEARANCE
INSPECTION [WL-3].)
2. Apply silicone sealant to the cylinder head as
shown.
DBG110AEB013
3. Tighten cylinder head cover bolts A and B.
Tightening torque @
1.5-2.9 N·m {16-29 kgf·cm, 14-25 in·lbf} @ ® ® @ © CD A
4. Tighten the cylinder head cover bolts in the order

ENGINE
FRONT
Tightening torque
4.9-8.8 N·m {50-89 kgf·cm, 44-77 in.lbf} (j) @ ® B
DBG110AEBR14
:i 01-10A-S2
H
,~

ENGINE MOUNTING [WL-C, WE-C] ..• 01-10B-2 PISTON RING CLEARANCE
,., ENGINE DISMOUNTING INSPECTION [WL-C, WE-C] •....••.. 01-10B-26
, [WL-C, WE-C] . . . . . • . . • . • • • . • • . . . . 01-10B-3 PISTON PIN CLEARANCE
TIMING BELT DISASSEMBLY INSPECTION [WL-C, WE-C] ..•••...• 01-10B-26
[WL-C, WE-C] . . . • • . . • • • • . . . . . • • • . 01-10B-4 CRANKSHAFT INSPECTION
CYLINDER HEAD DISASSEMBLY(I) [WL-C, WE-C] •.....••.••••••....•• 01-1 OB-27
[WL-C, WE-C] •••...••.•....••...• 01-10B-6 CRANKSHAFT OIL CLEARANCE
CYLINDER HEAD DISASSEMBLY (II) INSPECTION/REPAIR
[WL-C, WE-C] • . . • • • . . • . . • • . • . . . . . 01-10B-8 [WL-C, WE-C] .•••••..........•••.. 01-1 OB-28
CYLINDER BLOCK DISASSEMBLY (I) CRANKSHAFT END PLAY
[WL-C, WE-C] . . . • . . • • • • • • . • . . • • •. 01-10B-9 INSPECTION/REPAIR
CYLINDER BLOCK DISASSEMBLY (II) [WL-C, WE-C] •.•......••••.••...•• 01-1 OB-28
[WL-C, WE-C] .••...•.......••...• 01-10B-10 CONNECTING ROD
CYLINDER BLOCK DISASSEMBLY (III) INSPECTION [WL-C, WE-C] ...•..... 01-10B-29
[WL-C, WE-C] •.••••..•.••••••.... 01-10B-15 CONNECTING ROD OIL CLEARANCE
CYLINDER HEAD INSPECTION/REPAIR INSPECTION/REPAIR
[WL-C, WE-C] ......••.•••.•..•... 01-10B-16 [WL-C, WE-C] •.....•..•••.•••...•• 01-1 OB-29
VALVE INSPECTION [WL-C, WE-C] ... 01-10B-17 CONNECTING ROD SIDE CLEARANCE
VALVE GUIDE INSPECTION INSPECTION [WL-C, WE-C] ...•....• 01-10B-29
[WL-C, WE-C] ••••.•..•.••••••.... 01-10B-18 PISTON AND CONNECTING
VALVE GUIDE REPLACEMENT ROD INSPECTION [WL-C, WE-C] ••••• 01-10B-30
[WL-C, WE-C] . . . . . . • • • • • • • • . . • • .. 01-10B-18 BALANCE SHAFT INSPECTION
VALVE SEAT INSPECTION/REPAIR [WL-C, WE-C] •........•••••••...•• 01-1 OB-30
[WL-C, WE-C] •••...••....•.•..... 01-10B-19 BOLT INSPECTION [WL-C, WE-C] •..•• 01-10B-31
VALVE SPRING INSPECTION VALVE CLEARANCE INSPECTION
[WL-C, WE-C] ..•.••..•..••••..... 01-10B-20 [WL-C, WE-C] .•••••.••.......•••.. 01-1 OB-31
I
. CAMSHAFT INSPECTION VALVE CLEARANCE ADJUSTMENT
[WL-C, WE-C] ......••..•..•..•.•. 01-10B-20 [WL-C, WE-C] ....•.••..••......•.. 01-1 OB-32
CAMSHAFT OIL CLEARANCE GEAR CLEARANCE INSPECTION
INSPECTION [WL-C, WE-C] .•••••... 01-10B-21 [WL-C, WE-C] •••......••.••.•...•. 01-10B-33
CAMSHAFT END PLAY INSPECTION PLUNGER SPRING INSPECTION
[WL-C,WE-C] ...•••..•••••••..... 01-10B-21 [WL-C, WE-C] .•.•••.••..•....••... 01-1 OB-33
CYLINDER BLOCK CYLINDER BLOCK ASSEMBLY (I)
INSPECTION/REPAIR [WL-C, WE-C] • 01-10B-22 [WL-C, WE-C] ......•..•••......•.. 01-1 OB-34
DUAL-MASS FLYWHEEL CYLINDER BLOCK ASSEMBLY (II)
INSPECTION [WL-C, WE-C] .•••••... 01-10B-22 [WL-C, WE-C] •••......•..••••...•• 01-10B-37
OIL JET VALVE, NOZZLE CYLINDER BLOCK ASSEMBLY (III)
INSPECTION [WL-C, WE-C] •.....•.• 01-10B-25 > [WL-C, WE-C] ..••••.••........••.. 01-10B-43
PISTON INSPECTION CYLINDER HEAD ASSEMBLY (I)
[WL-C, WE-C] • • • . . . . . . . . . . . . .. • •. 01-10B-25 [WL-C, WE-C] ......••.•••......•.• 01-10B-45
PISTON CLEARANCE CYLINDER HEAD ASSEMBLY (II) ~
INSPECTION/REPAIR [WL-C, WE-C] •••......•..•..•...•. 01-10B-47
[WL-C, WE-C] . . . . • . . • • • . • • • • . . • • . 01-10B-25 TIMING BELT ASSEMBLY
[WL-C, WE-C] .•..••.••........••.. 01-10B-51
01-108-1
ENGINE MOUNTING [WL-C, WE-C]
DCF011002000W16
1. Install the SST to the cylinder head using the bolt
(99784 1020 or M1 OX1.2S, ST, length 20mm
{0.79 in}) as shown in the figure.
Tightening torque
43.1-60.S N·m {4.40-6.10 kgf.m, 31.S-44.S
ft.lbf}
2. Suspend the engine using the SST.
DBG110BWB89
3. Install the SST (arms) to the holes as shown in

the figure, and hand tighten the SST (bolts).
DBG110AEB002
4. Assemble the SSTs (bolts, nuts and plate) to the

specified positions.
DBG110AEB003
01-108-2
5. Adjust the SST (bolts) so that 20 mm {0.79 in} or
more of thread is exposed.
6. Align the SSTs (plate and arms) so that they are
I parallel by adjusting the SSTs (bolts and nuts).

7. Tighten the SSTs (bolts and nuts) to affix the SST
firmly.
DBG110AEB105
8. Mount the engine on the SST (engine stand).
Warning
• The self-locking brake system for the
engine stand may not operate if the
engine is held in an unbalanced position.
This could lead to sudden, rapid
movement of the engine and mounting
stand handle and cause serious injury.
Never hold the engine in an unbalanced
position, and always grasp the rotating
handle firmly when turning the engine. DBG110AEB004
,
9. Remove the SST (303-050 (49 UN30 3050)).
10. Drain the engine oil into a container.
11. Install the drain plug using new washer.
Tightening torque
29.4-41.2 N·m {3.0-4.2 kgf·m, 22-30 ft.lbf}
ENGINE DISMOUNTING [WL-C, WE-C] DCF011002000W17

1. Dismount in the reverse order of mounting.
01-108-3
TIMING BELT DISASSEMBLY [WL-C, WE-C]
DCF011002000W18
DBG110BEB014
1 Water pump 5 Idler

2 Vacuum pump 6 Timing belt
3 Timing belt cover (See 01-10B-5 Timing Belt Disassembly Note.)
4 Tensioner 7 Injector
(See 01-10B-5 Tensioner Disassembly Note.) 8 Cylinder head cover
01-108-4
Tensioner Disassembly Note
1. Turn the crankshaft clockwise and align the timing INTAKE EXHAUST
marks as shown in the figure. CAMSHAFT
CAMSHAFT
PULLEY PULLEY
DBG110BWB98
2. Turn the auto tensioner counterclockwise using

an Allen wrench. (Rotate the auto tensioner with a c
force of 39 N·m {4.0 kgf·m, 28.8 ft.lbf} or less.)
3. Insert a fixing pin of approx. 6 mm {O.24 in}
diameter into hole A to secure the auto tensioner.
t
4. Remove the bolts in the order of Band C, then
remove the auto tensioner.
Note 39 N·m {4.0 kgf·m, 28.8 ft·lbf}

• If the rod projects suddenly while removing MAX.
the auto tensioner, the air flows into the
pressure chamber and the rod could move
DBG110BEB033
slightly. If this occurs, bleed the air from the
pressure chamber using the following
procedure.
a 5. Assemble the auto tensioner to the engine.

'" 6. Turn the auto tensioner with a force of 39 N·m
{4.0 kgf·m, 28.8 ft·lbf} or less using an Allen
wrench, then turn it back slowly. Repeat this
procedure several times.
7. Verify that the rod has resistance when it is in the
most proJected position. If there is no resistance,
repeat the above procedure.
..... t
REPEAT
39 N·m SEVERAL
{4.0 kgf·m, TIMES ALLEN
28.8 ft·lbf} MAX. WRENCH
DBG110BWB999
Timing Belt Disassembly Note
Caution
• The following will damage the timing belt and shorten its life; forcefully twisting it, turning it inside
out, or getting oil or grease on it.
• After removing the timing belt, do not move the crankshaft and/or camshaft pulley from this
position because it can cause the valve and piston to contact and damage them.

reinstallation.
t ~~OTATION
~I ~
30 mm {1.2 in } MIN.
ARROW
~NG
DBG110BWB003
01-108-5
,-
" ..
!
CYLINDER HEAD DISASSEMBLY(I) [WL-C, WE-C]
DCF011002000W19
®
Ii)
DBG110BEB062
1 Camshaft pulley 5 Camshaft cap Lower

(See 01-108-7 Camshaft Pulley Disassembly 6 ECT sensor
Note.)
7 Cylinder head
2 Seal plate (See 01-108-7 Cylinder Head Disassembly Note.)
3 Camshaft cap upper 8 Cylinder head gasket
(See 01-108-7 Camshaft Cap Upper Disassembly
Note.)
4 Camshaft
01-108-6
-camshaft Pulley Disassembly Note
1. Hold the camshaft using a wrench on the cast hexagon.
caution
CAMSHAFT PULLEY
damage them.
DBG110BEB082
Camshaft Cap Upper Disassembly Note

DBG110BEB083
Camshaft Disassembly Note

1. Before removing the camshaft, inspect the camshaft oil clearance. (See 01-1 OB-21 CAMSHAFT OIL
CLEARANCE INSPECTION [WL-C, WE-C].)
Cylinder Head Disassembly Note

1. Remove bolts A.
DBG110BEB084
t·.'·.
"
01-108-7
--
CYLINDER HEAD DISASSEMBLY (II) [WL-C, WE-C]
DCF011002000W20
DBG110BEB016
Rocker arm 6 Valve spring

2 Pivot 7 Valve
3 Valve cap 8 Valve seal ,
4 Valve keeper (See 01-108-9 Valve Seal Disassembly Note.)
(See 01-1 OB-8 Valve Keeper Disassembly Note.) 9 Lower valve spring seat
5 Upper valve spring seat 10 Water outlet pipe
Valve Keeper Disassembly Note

1. Remove the valve keeper using the SST.
01-108-8
-
Valve Seal Disassembly Note
1. Remove the valve seal using the SST.
VALVE GUIDE
DBG110BEB085
CYLINDER BLOCK DISASSEMBLY (I) [WL-C, WE-C]

DCF011002000W21
iii
DBG110BEB075
1 Oil drain plug 3 IOil strainer

2 Oil pan 4 Oil pipe
t
(See 01-108-10 Oil Pan Disassembly Note.)
01-108-9
Oil Pan Disassembly Note
1. Remove the oil pan using a separator tool.
DBG110BEB086
CYLINDER BLOCK DISASSEMBLY (II) [WL-C, WE-C]

DCF011002000W22
mJ
3
DBG110BEB019
01-108-10
, 2
3
Crankshaft pulley
(See 01-108-11 Crankshaft Pulley Disassembly
Note.)
Seal plate
Supply pump pulley
(See 01-108-11 Supply Pump Pulley Disassembly
9
10
Timing gear case
(See 01-108-14 Timing Gear Case Disassembly
Note.)
Dual-mass flywheel
(See 01-108-14 Dual-mass flywheel Disassembly
Note.)
Note.) 11 End plate
4 Timing gear cover 12 Rear cover
(See 01-108-11 Timing Gear Cover Disassembly (See 01-108-14 Rear Cover Disassembly Note.)
Note.) 13 Seal plate
5 Oil pump 14 Oil pump cover
6 Supply pump gear 15 Driven gear
(See 01-108-12 Supply Pump Gear Disassembly
Note.) 16 Plug
Timing gear 17 Plunger spring
7
Supply pump 18 Control plunger
8
19 Oil pump body
Crankshaft Pulley Disassembly Note

1. Remove the crankshaft pulley using the SST.
, DBG110BEB064
Supply Pump Pulley Disassembly Note

1. Remove the supply pump pulley using the SST.
DBG110BEB055
Timing Gear Cover Disassembly Note

1. Remove the timing gear cover using a separator
tool.
SEPARATOR TOOL
DBG110BEB087
01-108-11
with a rag,
Supply Pump Gear Disassembly Note

approximately 30° BTOC (about 13 teeth on the
gear).
DBG110BEB089
3. Verify that the end-gap (V groove) of the timing

gear case and the chip cut gear of the fuel
injection pump gear are aligned.
Note SUPPLY
• If the chip cut gear is hard to find, move the PUMP GEAR
o
supply pump gear on notch back and forth,
then check the chip cut gear.
SUPPLY CHIP CUT GEAR

PUMP GEAR
(HELICAL GEAR)
ABOUT3.0mm
{O.12 in}
DBG110BEB90
01-108-12
-
4. Fix the scissors gear to the supply pump gear using a lock bolt (M6x1.0; length under the bolt head is
approximately 16 mm {O.63 in}).
Warning
• When removing the supply pump gear, be sure to secure the scissors gear to the supply pump
gear using a lock bolt (M6x1.0; length under the bolt head is approximately 16 mm {O.63 in}).
Otherwise, the scissors gear will rotate with the spring force, causing personal injury.
caution
• When removing the supply pump gear, be sure to secure the scissors gear to the supply pump
gear using a look bolt (M6x1.0; length under the bolt head is approximately 16 mm {O.63 in}) to
prevent the scissors gear form rotating with the spring force. Otherwise, the scissors gear will not
align with the supply pump gear, and the supply pump gear with the scissors gear will not engage
with the idler gear.
Note
• The supply pump gear with a scissors
gear has a lock bolt hole.
DBG110BEB091
5. Hold the crankshaft using the SST and loosen the

gear nut.
6. Remove the supply pump gear using the SST and

bolt (M6X1.0, Length 30mm {1.18 in}).
01-108-13
-----------------------------------------~~--~------~--------------------------- ~~
Timing Gear Case Disassembly Note ~
1. Remove the timing gear case using the separator ,------------:-----------.., ~,
:ti'
tool. ~
DBG110BEB094
Dual-mass flywheel Disassembly Note

1. Remove the Dual-mass flywheel using the SST.
:.' I ! I
DBG110BEB034
Rear Cover Disassembly Note

with a rag.
RAG
DBG110BEB095
01-108-14
CYLINDER BLOCK DISASSEMBLY (III) [WL-C, WE-C]
DCF011002000W23
16
I 13
~
I
11
DBG110BEB021
1 Balance shaft 9 Piston

2 Connecting rod cap 10 Connecting rod
(See 01-10B-16 Connecting Rod Cap Disassembly 11 Main bearing cap
Note) (See 01-10B-16 Main Bearing Cap Disassembly
3 Lower connecting rod bearing Note)
4 Piston, connecting rod 12 Lower main bearing, lower thrust bearing
(See 01-10B-16 Piston, Connecting Rod 13 Crankshaft
Disassembly Note) (See 01-10A-16 Crankshaft Disassembly Note)
5 Upper connecting rod bearing 14 Upper main bearing, upper thrust bearing
6 Piston ring Oil jet valve, nozzle
15
7 Piston pin clip 16 Cylinder block
8 Piston pin
(See 01-10B-16 Piston Pin Disassembly Note)
01-108-15
Connecting Rod Cap Disassembly Note
1. Before removing the connecting rod cap, inspect the connecting rod side clearance. (See 01-1 OB-29
CONNECTING ROD SIDE CLEARANCE INSPECTION [WL-C, WE-C].)
Piston, Connecting Rod Disassembly Note

1. Before removing the piston and connecting rod, inspect the connecting rod oil clearance. (See 01-1 OB-29
CONNECTING ROD OIL CLEARANCE INSPECTION/REPAIR [WL-C, WE-C].)
2. Inspect the oscillation torque. (See 01-1 OB-30 PISTON AND CONNECTING ROD INSPECTION [WL-C, WE-
C].)
Piston Pin Disassembly Note

1. Remove the piston pin using the SST.
,. . ..
DBG110BEB096
Main Bearing Cap Disassembly Note

1. Before removing the main bearing cap, inspect the crankshaft end play. (See 01-1 OB-28 CRANKSHAFT END
PLAY INSPECTION/REPAIR [WL-C, WE-C].)
2. Loosen the main bearing cap bolts in two or three
Crankshaft Disassembly Note

1. Before removing the crankshaft, inspect the main journal oil clearance. (See 01-1 OB-28 CRANKSHAFT OIL
CLEARANCE INSPECTION/REPAIR [WL-C, WE-C].)
CYLINDER HEAD INSPECTION/REPAIR [WL-C, WE-C]

DCF011 01 01 00W02
1. Inspect the cylinder head surface for cracks. Replace the cylinder head if necessary.
2. Inspect for the following and repair or replace.
(1) Sunken valve seats
(2) Excessive camshaft oil clearance and end play
3. Measure the cylinder head for distortion in the
seven directions as shown in the figure. Y

X distortion: 0.02 mm {o.oooa in} max.
Y distortion: 0.05 mm {0.0020 in} max.
4. If the cylinder head distortion exceeds the

maximum, replace the cylinder head. Do not
attempt to repair a cylinder head by milling or
grinding.
DBG110BEB080
01-108-16
-5. Measure the manifold contact surface distortion as shown in the figure.
Maximum manifold contact surface distortion
, 0.05 mm {0.002 in} max.
6. If the distortion exceeds the maximum, grind the

surface or replace the cylinder head.
Maximum manifold contact surface grinding

0.15 mm {0.0059 in} max.
DBG110BEB140
VALVE INSPECTION [WL-C, WE-C]

DCF011012111W04
1. Measure the valve head margin thickness of each
valve. Replace the valve if necessary.
Standard valve margin thickness

THICKNESS -Ii
r------.L..,~
IN: 1.55-1.85 mm {0.061-0.072 in}
EX: 1.80-2.10 mm {0.070-0.082 in}
,
2. Measure the length of each valve. Replace the
valve if necessary.
LENGTH
IN: 111.65-112.25 mm {4.394-4.413 in}
DBG110BEB098
EX: 111.6-112.2 mm {4.390-4.409 in}

IN: 111.50 mm {4.390 in}
EX: 111.45 mm {4.388 in}
3. Measure the stem diameter of each valve in the X

and Y directions at the three points (A, B, and C)
shown in the figure. Replace the valve if
necessary.

IN: 5.970-5.985 mm {0.2350-0.2356 in}
EX: 5.965-5.980 mm {0.2348-0.2354 in}

IN: 5.920 mm {0.2330 in}
EX: 5.915 mm {0.2328 in}
DBG110BEB099
01-108-17
VALVE GUIDE INSPECTION [WL-C, WE-C]
DCF011010280W03
1. Measure the inner diameter of each valve guide in
the X and Y directions at the three pOints (A, B,
and C) shown in the figure. Replace the valve
guide if necessary.
A
Standard valve guide inner diameter
S.025-S.045 mm {0.2372-0.2379 in}
B
DBG110BEB100
2. Measure the protrusion height (dimension A) of

each valve guide without lower valve spring seat.
Replace the valve guide if necessary.
Standard valve guide height

IN: 15.0-15.5 mm {0.59-0.S1 in} @..L..-__ I_-U
EX: 17.0-17.5 mm {0.S7-0.S9 in}
DBG110BEB101
VALVE GUIDE REPLACEMENT [WL-C, WE-C]

DCF011 01 0280W04
Valve Guide Removal
• Remove the valve guide from the combustion
chamber side using the SST.
DBG110BEB102
Valve Guide Installation

1. Mark the dimension L position on the valve guide.
Depth L VALVE GUID~! !

IN: 15.0-15.5 mm {0.59-0.S1 in} L
EX: 17.0-17.5 mm {0.S7-0.SS in} I
:
I
: r--
I I
I I
I I
I I
I I
I I
I I
I I
\.L..L
THE CYLINDER HEAD SIDE
DBG110BEB110
01-108-18
-2. When the valve guide nears the dimension L
position while it is being tapped in, verify the
dimension L position again with vernier calipers to
, prevent deviation in insertion.
3. Verify that the valve guide projection height is

IN: 1S.0-1S.S mm {0.S9-0.61 in}
EX: 17.0-17.S mm {0.67-0.68 in}
VALVE SEAT INSPECTION/REPAIR [WL-C, WE-C]

DCF011 01 01 02W02
1. Measure the seat contact width. If necessary,
resurface the valve seat using a 4So valve seat
cutter and/or resurface the valve face.

1.3-1.9 mm {0.OS2-0.074 in} SEAT CONTACT
WIDTH
,
DBG110AEB109
2. Verify that the valve seating position is at the center of the valve face. .
1. If the seating position is too high, correct the valve seat using a 60° cutter, and then a 4So cutter.
2. If the seating position is too low, correct the
valve seat using a 30° cutter, and a 4So cutter.
IN EX
Valve seat angle
IN: 4So
~
EX: 4So oo
45°
30°
DBG110AEB078
3. Measure the receded amount from the cylinder

head surface. If it exceeds the maximum, replace
the cylinder head.

IN: 0.79-1.27 mm {0.039-0.0S0 in}
EX: 0.84-1.32 mm {0.033-0.0S1 in}

IN: 1.68 mm {0.066 in}
EX: 1.73 mm {0.062 in}
DBG110AEB112
01-108-19
1
I,
•:".,1,.• .•.• •
'Ii
VALVE SPRING INSPECTION [WL-C, WE-C]
DCF011012125W02
1. Apply a pressing force to the pressure spring and
check the spring height. Replace the valve spring
if necessary.
Valve spring installation pressing force

172.9-195.6 N {15.67-17.74 kgf, 34.48-
39.02Ibf}
Valve spring installation height

39.0 mm {1.53 in}
DBG0110AEB11
2. Measure the amount the valve spring is out-of-

square. Replace the valve spring if necessary.
Maximum valve spring out-of-square

2.0 0 (1.60mm {0.062 in})
DBG110AEB079
CAMSHAFT INSPECTION [WL-C, WE-C]

DCF011012420W04
1. Set the No.1 and No.5 journals on V-blocks.
Measure the camshaft runout. Replace the
camshaft if necessary.
Maximum camshaft run out

0.03 mm {0.001 in} max.
DBG110AEB114
2. Measure the cam lobe height at the two points as

shown in the figure. Replace the camshaft if
necessary.
D o=r
++
IN: 42.067-42.167 mm {1.6561-1.6601 in}
EX: 41.949-42.049 mm {1.6515-1.6554 in}
Minimum cam lobe height ++

IN: 41.717 mm {1.6424 in}
EX: 41.599 mm {1.6377 in}
DBG110AEB080
01-108-20
directions at the two points (A and 8) as shown in
the figure. Replace the camshaft if necessary.
t Standard cam journal diameter

No.1: 31.940-31.965 mm {1.2575-1.2582
in}
No.2-No.4: 25.910-25.935 mm {1.0201-
1.0210 in}
No.5: 25.940-25.965 mm {1.0212-1.0222
in}
DBG110AEB081
No.1: 31.890 mm {1.2555 in}
No.2-No.4: 25.860 mm {1.0181 in}
No.5: 25.890 mm {1.0193 in}
CAMSHAFT OIL CLEARANCE INSPECTION [WL-C, WE-C)

DCF011012420W05
2. Install the camshaft cap. (See 01-108-49 Camshaft Cap Upper Assembly Note.)
3. Remove the camshaft cap. (See 01-108-7 Camshaft Cap Upper Disassembly Note.)
4. Measure the oil clearance. Replace the cylinder
head if necessary.

No.1: 0.035-0.081 mm {0.0014-0.0031 in}
No.2-4: 0.065-0.111 mm {0.0026-0.0043
in}
No.5: 0.056-0.081 mm {0.0014-0.0031 in}

No.1: 0.12 mm {0.0047 in}
No.2-4: 0.15 mm {0.0059 in}
DBG110BEB053
No.5: 0.16 mm {0.0063 in}
CAMSHAFT END PLAY INSPECTION [WL-C, WE-C)

DCF011012420W06
1. Install the camshaft cap. (See 01-108-49 Camshaft Cap Upper Assembly Note.)
2. Measure the camshaft end play. Replace the ,---------------------,
cylinder head or camshaft if necessary.
Standard camshaft end play

0.030-0.160 mm {0.0012-0.0062 in}
Maximum camshaft end play

0.20 mm {0.0078 in}
3. Remove the camshaft cap. (See 01-108-7

Camshaft Cap Upper Disassembly Note.)
DBG110BEB109
01-108-21
CYLINDER BLOCK INSPECTION/REPAIR [WL-C, WE-C]
DCF011010300W02
1. Measure the distortion of the cylinder block top
surface in the seven directions as shown in the y
figure. Replace if necessary.

DBG110AEB115
2. Measure the cylinder bore using the cylinder gauge. Measurement positions are in the X and Y directions at 83
mm {3.27 in} (WL-C) or 88 mm {3.46 in} (WE-C) below the top surface of the cylinder.
• If the cylinder bore exceeds the wear limit,
replace the cylinder block or rebore the X
cylinder and install the oversized pistons so
that the specified piston-to-cylinder clearance
is obtained.
WL-C 83.0 mm {3.27 in}
WE-C 88.0 mm {3.46 in}
ffi
W y
Yll
Note
• Base the boring diameter on the diameter of
an oversized piston. All cylinders must be
the same diameter.
Cylinder bore size [WL-C]

DBG110BEB047
Standard: 93.000-93.022 mm {3.6615-
3.6622 in}
0.25 {0.01} oversize: 93.250-93.272 mm {3.6713-3.6721 in}
0.50 {0.02} oversize: 93.500-93.522 mm {3.6811-3.6819 in}
Cylinder bore size [WE-C]

Standard: 96.000-96.022 mm {3.6615-3.6622 in}
0.25 {0.01} oversize: 96.250-96.272 mm {3.7893-3.7902 in}
0.50 {0.02} oversize: 96.500-96.522 mm {3.7992-3.8000 in}
Cylinder bore wear limit

0.15 mm {0.0059 in}
DUAL-MASS FLYWHEEL INSPECTION [WL-C, WE-C]

DCF011011500W01
Caution
• Do not rework the flywheel if it is distorted.
• Do not clean the dual mass flywheel with any kind of fluid. Clean the flywheel with a dry cloth only.
• Do not clean the gap between the primary and secondary mass. Only clean the bolt connection
surface and the clutch surface.
Note
• Correct slight scratches and discoloration
using sandpaper.
• Inspect the runout of the surface that
contacts the clutch disc with the flywheel
installed to the crankshaft.
1. Inspect the flywheel.
Cracks
Worn ring gear teeth
Chipped or cracked ring gear teeth
Surface that contacts the clutch disc for
scratches, nicks, and discoloration.
• If there is any malfunction, replace the C3U0510W004
flywheel.
01-108-22
-
2. Verify that the center of the flywheel does not move.
(1) Rotate the flywheel or attempt to move it up
and down, and left and right to verify that the
center of the flywheel does not move.
• If there is any movement as indicated by
the arrows in the figure, replace the
flywheel with a new one.
3. Verify that the secondary mass rotates by 15

teeth or more.
• If it rotates by 15 teeth or more, replace the
dual-mass flywheel.
D3E510ZW8001
4. Inspect for locating dowels touching the primary

mass of the flywheel.
Caution
• Make sure that the three locating dowels
are installed.
• If the locating dowels are touching the primary

mass of the flywheel, replace the flywheel
with a new one.
5. Visually inspect the secondary mass.
• If there is any damage, replace the dual-mass
1r1nnnnnnnnr
--:--- -B3E0510W056
flywheel.
6. Visually inspect the ring gear on the dual-mass
flywheel. RING GEAR
flywheel.
D3E510ZW8002
01-108-23
7. Inspect the welded area of the dual-mass
flywheel for grease leakage.
• If there is grease leakage, replace the dual-
mass flywheel.
8. Inspect the dual-mass flywheel runout.
Flywheel maximum runout

1.5 mm {O.059 in}
• If it is more than the maximum specification,

replace the dual-mass flywheel.
9. Inspect the dual-mass flywheel for the amount of

guide pin projection.
• If not within the specification, replace the
dual-mass flywheel.
11mm {O.4330}
D3E510ZWB005
10. Rotate the secondary mass left and right and

verify that it rotates within a range of five teeth
without resistance.
• If there is any malfunction, replace the dual-
mass flywheel.
11. Inspect the dual-mass flywheel for cracks.
• If there are cracks, replace the dual-mass
flywheel.
D3E510ZWB006
01-108-24
-OIL JET VALVE, NOZZLE INSPECTION [WL-C, WE-C]
DCF011 01 0730W02
1. Apply compressed air to oil jet valve A and verify that air passes through oil jet valve B. If not, replace the oil jet
valve.
Oil jet air pressure

137.6-196.4 kPa {1.4-2.0 kgf/cm 2 , 20-28 psi}
2. Check the oil jet nozzle for clogs. Replace the

nozzle if necessary.
DBG110AEB085
PISTON INSPECTION [WL-C, WE-C]

DCF011011010W06
1. Measure the outer diameter of each piston at right angle (90 0 ) to the piston pin, 20 mm {0.79 in} below the oil
ring land lower edge.
Piston diameter [WL-C]

Standard: 92.918-92.944 mm {3.6582-
3.6592 in}
0.25 {0.010} oversize: 93.153-93.179 mm
{3.6675-3.6684 in}
t 0.50 {0.020} oversize: 93.403-93.429 mm

{3.6773-3.6782 in}
20mm
Piston diameter [WE-C] {O.79 in}
Standard: 95.918-95.944 mm {3.7763-
3.7773 in}
DBG110AEBR86
0.25,{0.010} oversize: 96.153-96.179 mm
{3.7856-3.7865 in}
0.50 {0.020} oversize: 96.403-96.429 mm {3.7954-3.7964 in}
PISTON CLEARANCE INSPECTION/REPAIR [WL-C, WE-C]

DCF011011010W07
1. Measure the piston-to-cylinder clearance. Replace the piston or rebore the cylinders to fit the oversized piston
if necessary.
Standard piston clearance

0.071-0.089 mm {0.0015-0.0022 in}
Maximum piston clearance

0.15 mm {0.0059 in}
2. If the piston is replaced, the piston rings must also be replaced.
01-108-25
PISTON RING CLEARANCE INSPECTION [WL-C, WE-C]
DCF011011010WOS
1. Measure the piston ring-to-ring land clearance
around the entire circumference. Replace the
piston and piston ring if necessary.
Standard piston ring clearance [WL-C]

Top: 0.06-0.10 mm {0.0024-0.0039 in}
Second: 0.04-0.08 mm {0.0016-0.0031 in}
Oil: 0.02-0.06 mm {0.0012-0.0023 in}
Standard piston ring clearance [WE-C]

Top: 0.06-0.10 mm {0.0024-0.0039 in}
Second: 0.04-0.08 mm {0.0016-0.0031 in}
DBG110AEBl16
Oil: 0.02-0.06 mm {0.0008-0.0023 in}
Maximum piston ring clearance

0.15 mm {0.0059 in}
2. Insert the piston ring into the cylinder by hand and use the piston to push it to the bottom of the ring travel.
3. Measure each piston ring end gap with a feeler
gauge. Replace the piston ring, if necessary.
Standard piston ring end gap [WL-C]

Top: 0.22-0.32 mm {0.0087-0.0125 in}
Second: 0.49-0.64 mm {0.0193-0.0251 in}
Oil: 0.22-0.52 mm {0.0087-0.0204 in}
Standard piston ring end gap [WE-C]

Top: 0.23-0.33 mm {0.0091-0.0129 in}
Second: 0.50-0.65 mm {0.0197-0.0255 in}
Oil: 0.22-0.52 mm {0.0087-0.0204 in}
Maximum piston ring end gap

1.0 mm {0.039 in}
PISTON PIN CLEARANCE INSPECTION [WL-C, WE-C]

DCF011011010W09
1. Measure each piston pin bore diameter in the X
and Y directions at the four points (A, B, C, and D)
Standard piston pin bore diameter
u:d
33.997-34.007 mm {1.3384-1.3388 in}
DBG110AEB088
2. Measure each connecting rod small end inner

diameter in the X and Y directions as shown in the x
figure.
Standard connecting rod small end inner ~-+--~IY
diameter
34.012-34.033 mm {1.3391-1.3398 in}
DBG110AEB117
01-108-26
-3. Measure each piston pin diameter in the X and Y
x
l
-o--y
directions at the four points (A, B, C and D) as
Standard piston pin diameter

33.994-34.000 mm {1.3384-1.3385 in} t
4. Calculate the piston pin-to-piston pin bore
clearance. Replace the piston and/or piston pin if
necessary.
o
Standard piston pin-to-piston pin bore
DBG110AEBl18
clearance
-0.003-0.013 mm {-0.0001-0.0005 in}
5. Calculate the connecting rod small end-to-piston pin clearance. Replace the connecting rod or piston pin.
Standard connecting rod small end-to-piston pin clearance

0.012-0.039 mm {0.00048-0.0015 in}
CRANKSHAFT INSPECTION [WL-C, WE-C]

DCF011011301W04
1. Measure the crankshaft runout. Replace the
crankshaft if necessary.
Maximum crankshaft runout

0.05 mm {0.002 in}
DBG110AEB089
2. Measure the journal diameter in the X and Y

directions at the two points (A and B) as shown in A B
the figure. Replace the crankshaft or grind the
journal and install the undersize bearing if x
necessary.
Main journal diameter [No.1 ,2,4,5] I---+--.... jy

Standard: 66.937-66.955 mm {2.6354-
2.6360 in}
0.25 {0.010} undersize: 66.687-66.705 mm
{2.6255-2.6261 in}
0.50 {0.020} undersize: 66.437-66.455 mm
DBG 11 OAEB090
{2.6157-2.6163 in}
0.75 {0.030} undersize: 66.187-66.205 mm
{2.6058-2.6064 in}
Main journal diameter [No.3]

Standard: 66.920-66.938 mm {2.6347-2.6353 in}
0.25 {0.010} undersize: 66.670-66.688 mm {2.6367-2.6373 in}
0.50 {0.020} undersize: 66.420-66.438 mm {2.6150-2.6156 in}
0.75 {0.030} undersize: 66.170-66.188 mm {2.6052-2.6058 in}
Main journal wear limit

0.05 mm {0.002 in}
Main journal out-of-round

0.03 mm {0.001 in}
01-108-27
Crank pin diameter [WL-C]
Standard: 54.940-54.955 mm {2.1630-2.1635 in}

-
0.25 {0.010} undersize: 54.690-54.705 mm {2.1532-2.1537 in}
0.50 {0.020} undersize: 54.440-54.455 mm {2.1434-2.1438 in}
0.75 {0.030} undersize: 54.190-54.205 mm {2.1335-2.1340 in} t
Crank pin diameter [WE-C]
Standard: 56.940-56.955 mm {2.2417-2.2423 in}
0.25 {0.010} undersize: 56.690-56.705 mm {2.2318-2.2324 in}
0.50 {0.020} undersize: 56.440-56.455 mm {2.2220-2.2226 in}
0.75 {0.030} undersize: 56.190-56.205 mm {2.2122-2.2128 in}
Crank pin wear limit

0.05 mm {0.0020 in}
Crank pin out-of-round

0.03 mm {0.0012 in}
CRANKSHAFT OIL CLEARANCE INSPECTION/REPAIR [WL-C, WE-C]

DCF011011301WOS
2. Install the main bearing cap. (See 01-1 OB-35 Main Bearing Cap Assembly Note.)
3. Remove the main bearing cap. (See 01-10B-16 Main Bearing Cap Disassembly Note.)
4. Measure the main journal oil clearance. If the clearance exceeds the maximum, replace the main bearing or
grind the main journal and install the undersize bearings so that the specified oil clearance is obtained.

No.1, 2, 4, 5: 0.027-0.045 mm {0.0010-0.0017 in}
No.3: 0.044-0.062 mm {0.0017-0.0024 in}
Maximum main journal clearance

0.08 mm {0.003 in}

Standard: 2.006-2.021 mm {0.0789-0.0794 in}
0.25 {0.010} undersize:.2.124-2.134 mm {0.0836-0.0838 in}
0.50 {0.020} undersize: 2.249-2.259 mm {0.0885-0.0888 in}
0.75 {0.030} undersize: 2.374-2.384 mm {0.0934-0.0937 in}
CRANKSHAFT END PLAY INSPECTION/REPAIR [WL-C, WE-C]

DCF011011301W06
1. Install the main bearing cap. (See 01-1 OB-35 Main Bearing Cap Assembly Note.)
2. Measure the crankshaft end play. If the end play ,-----------;--;----------,
exceeds the maximum, replace the thrust bearing
or grind the crankshaft and install an oversized
bearing so that the specified end play is obtained.
Standard crankshaft end play

0.040-0.282 mm {0.0016-0.0111 in}
Maximum crankshaft end play

0.3 mm {0.01 in}

DBG110AEB120
Standard: 2.455-2.505 mm {0.0967-0.986
in}
0.35 {0.010} oversize: 2.630-2.680 mm {0.1036-0.1055 in}
3. Remove the main bearing cap. (See 01-10B-16 Main Bearing Cap Disassembly Note.)
01-108-28
-CONNECTING ROD INSPECTION [WL-C, WE-C]
DCF011011211W04
1. Measure each connecting rod for bending and
distortion. Replace the connecting rod if
necessary.
Connecting rod bending

0.075 mm {0.0030 in} max./50 mm {1.968 in}
Connecting rod distortion

0.18 mm {0.0070 in} max./50 mm {1.968 in}
Connecting rod center-to-center distance

[WL-C]
DBG110AEB119
162.96-163.04 mm {6.416-6.418 in}
Connecting rod center-to-center distance [WE-C]

157.96-158.04 mm {6.219-6.222 in}
CONNECTING ROD OIL CLEARANCE INSPECTION/REPAIR [WL-C, WE-C]

DCF011011211W05
2. Install the connecting rod cap. (See 01-108-36 Piston, Connecting Rod Assembly Note.)
4. Measure the crankpin oil clearance. If the
clearance exceeds the maximum, replace the
connecting rod bearing or grind the crankpin and
use undersized bearings so that the specified
clearance is obtained.
Standard connecting rod oil clearance

0.025-0.052 mm {0.0009-0.0020 in}
Maximum connecting rod oil clearance

0.08 mm {0.003 in}
DBG110AEB121
Connecting rod bearing thickness
Standard: 1.507-1.516 mm {0.0592-0.0595
in}
0.25 {0.010} undersize: 1.624-1.634 mm {0.0638-0.0642 in}
0.50 {0.020} undersize: 1.749-1.759 mm {0.0687-0.0691 in}
0.75 {0.030} undersize: 1.874-1.884 mm {0.0737-0.0740 in}
CONNECTING ROD SIDE CLEARANCE INSPECTION [WL-C, WE-C]

DCF011011211W06
1. Install the connecting rod cap. (See 01-108-36 Piston, Connecting Rod Assembly Note.)
2. Measure the connecting rod large end side
clearance. Replace the connecting rod and cap if
necessary.
Standard connecting rod side clearance

0.110-0.262 mm {0.0043-0.01 03 in}
Maximum connecting rod side clearance

0.35 mm {0.014 in}

DBG110AEB122
01-108-29
PISTON AND CONNECTING ROD INSPECTION [WL-C, WE-C]
DCF011011010W10
• Check the oscillation torque as shown. If the large
end does not drop by its own weight, replace the
piston or the piston pin.
DBG110AEB093
BALANCE SHAFT INSPECTION [WL-C, WE-C]

DCF011 01 0300W03
1. Install the balance shaft and tighten the thrust plate fitting bolt.
Tightening torque
7.85-10.8 N·m {80-110 kgf·m, 70-95 in·lbf}
2. Measure the balance shaft end play. Replace the

balance shaft and/or cylinder block if necessary.
Balance shaft Standard end play

0.04-0.16 mm {0.002-0.006 in}
DBG110AEB094

directions at the two points (A and 8) as shown in A B
the figure. Replace the balance shaft if necessary. x
Standard diameter
Front: 41.945-41.960 mm {1.6514-1.6519
in} I----j----/ Y
Center: 39.945-39.960 mm {1.5727-1.5732
in}
Rear: 37.975-37.990 mm {1.4951-1.4956
in}
DBG110AEB095
4. Measure the balance shaft bore in the cylinder

block. Calculate the balance shaft-to-balance
shaft bore clearance. Replace the balance shaft
and/or cylinder block if necessary.
Standard clearance
Front, rear: 0.050-0.115 mm {0.0020-
0.0045 in}
Center: 0.080-0.145 mm {0.0032-0.0057 in}
DBG110AEB096 f)
i
i
I:
i: I 01-108-30
w
1:11.1
-
BOLT INSPECTION [WL-C, WE-C]
DCF011010135W02
• Measure the length of each bolt. Replace the bolt
if necessary.

Bolt head mark W
4.007 in}
Bolt head mark N
4.480 in}
DBG110AEB097
Bolt head mark I
5.905 in}

Connecting rod cap bolt length

VALVE CLEARANCE INSPECTION [WL-C, WE-C]

DCF011012111W05
2. Turn the crankshaft and align the timing mark so that the piston of the No.1 or NO.4 cylinders is at TDC of
.. compression.
• 3. Measure valve clearances A with the No.1 B A B A
cylinder at TDC of compression, and those of 8
with the No.4 cylinder at TDC of compression.
• If it is not within the specification, adjust and EX
recl:leck the valve clearance. (See 01-108-32
VALVE CLEARANCE ADJUSTMENT [WL-C,
WE-C].)
IN
B B A A
DBG110BEB023
CAMSHAFT
Valve clearance [Engine cold] FEELER
IN: 0.10-0.16 mm {0.0040-0.0062 in}
~~~~f!!
EX: 0.17-0.23 mm {0.0067-0.0090 in}

GAU\_E___
5. Install the cylinder head cover.
ROCKER ARM
DBG110BTBRR5
01-108-31
VALVE CLEARANCE ADJUSTMENT [WL-C, WE-C]
DCFOll012111W06
Caution
• Loosening the locknut and the adjust
screw while the cam lobe is not pressing
down the rocker arm will damage the
claw of the rocker arm. When loosening
the locknut and the adjust screw, rotate CAM LOBE
the crankshaft clockwise and be sure that
the cam lobe presses down the rocker
arm firmly as shown in the figure.
CLAW
2. Turn the crankshaft and align the timing mark so ROCKER ARM
DBGll0BTBRR6
TOC of compression.
3. Adjust the valve clearances A with the No.1
cylinder at TOC of compression, and those of B
with the No.4 cylinder at TOC of compression.
DBG 11 OBEB023
Valve clearance [Engine cold]

FEELER
IN: 0.10-0.16 mm {0.0040-0.0062 in}
~~~-..,...g~
EX: 0.17-0.23 mm {0.0067-0.0090 in}
GAU\_E_____
Tightening torque (lock nut)
20-24 N·m {2.1-2.4 kgf.m, 15-17 ft.lbf}

5. Install the cylinder head cover.
ROCKER ARM
DBG110BTBRR5
,.!
01-108-32
. 'i
Ii ·1;
-
GEAR CLEARANCE INSPECTION [WL-C, WE-C]
DCF011019220W02
1. Measure the following clearance.
• If it exceeds the maximum specification, replace the gear and/or pump body.
·.a
.;
~.
0.10-0.19 mm {0.0040-0.0074 in}

0.20 mm {0.008 in}
DBG110AEB101

0.04-0.09 mm {0.0016-0.0035 in}

0.15 mm {0.0059 in}
DBG110AEB102
PLUNGER SPRING INSPECTION [WL-C, WE-C]

DCF011014116W02
1. Apply pressing force to the pressure spring and
check· the spring height. Replace the plunger
spring if necessary.

43.8 mm {1.72 in}
DBG110AEB103
01-108-33
MECHANICAL [WL-C, WE-C)
CYLINDER BLOCK ASSEMBLY <I> [WL-C, WE-C]
DCF0110020001lV24
46.5-51.5
{4.8-5.2,34.1-37.9}
+82.5° -97.5°
12-18 N·m {123-183 kgf.cm,

7.8-10.8 N·m 107-159 in·lbf}
{80-11 0 kgf·cm,
70-95 in·lbf}
14.5-34.5 {1.5-3.5, 11-25}

+74.0-82.0 {7.6-8.3, 55-60}
Loosen all the bolts (until bolts are torque·free)
+ 14.5-34.5 {1.5-3.5, 11-25}
+42.5-45.5 {4.4-4.6, 32-33}
+90°-105°
DBG110BEB052
1 Cylinder block 8 Piston

(8ee01-108-35 Piston, Connecting Rod, Piston Pin
2 Oil jet valve, nozzle
Assembly Note.)
3 Upper main bearing, upper thrust bearing
9 Piston pin
4 Crankshaft (8ee01-108-35 Piston, Connecting Rod, Piston Pin
5 Lower main bearing, lower thrust bearing Assembly Note.)
6 Main bearing cap 10 Piston pin clip
(8ee01-108-35 Main 8earing Cap Assembly 11 Piston ring
Note.) (8ee01-108-36 Piston Ring Assembly Note.)
7 Connecting rod 12 Upper connecting rod bearing
(8ee01-108-35 Piston, Connecting Rod, Piston Pin
Assembly Note.)
II
01-108-34
~!:!
- piston, connecting rod 15 IConnecting rod cap
'-13
(8ee01-10B-36 Piston, Connecting Rod Assembly 16 Balance shaft
Note.)
J 14 Lower connecting rod bearing
Main Bearing Cap Assembly Note

1. Apply clean engine oil to the bolt threads and seat faces of the lower cylinder block bolts.
2. Tighten the bolts in two or three steps in the order 8 4 1
shown in the ~igure.
Tightening procedure
(1) 14.5-34.5 N·m {1.5-3.5 kgf.m, 11-25
ft·lbf}
(2) 74.0-82.0 N·m {7.6-8.3 kgf·m, 55-60
ft·lbf}
(3) Loosen all the bolts (until bolts are
torque-free).
(4) 14.5-34.5 N·m {1.5-3.5 kgf·m, 11-25
ft.lbf}
DBG110AEB271
(5) 42.5-45.5 N·m {4.4-4.6 kgf.m, 32-33
ft.lbf}

by turning each 90°-105° as in Step 2.
, PAINT MARK
DBG110AEB072
Piston, Connecting Rod, Piston Pin Assembly Note

1. Install one piston pin clip.
2. Assemble the piston and connecting rod in the direction indicated in the figure.
3. Apply clean engine oil to the piston pin.
4. Install the piston pin until the pin contacts the clip
FMARK
as shown. If the pin cannot be installed easily,
heat the piston.
PROJECTION FOR ALIGNING

CONNECTIOG ROD BEARING
DPE110ZE1R18
01-108-35
Piston Ring Assembly Note
1. Install the oil ring.
2. Install the second ring with R mark side upward.
3. Install the top ring with tapered face side upward.
SECTION OF TOP RING
==( )
SECTION OF SECOND RING
DBG110AEBR96
Piston, Connecting Rod Assembly Note

1. Insert the piston and connecting rod assembly
into the cylinder with the F mark facing the front of
the engine.
2. Tighten the connecting rod cap bolts in two or
three steps.
FMARK
Tightening torque
46.5-51.5 N·m {4.8-5.2 kgf.m, 34.3-37.9
ft.lbf}
3. Put a paint mark on each bolt.

DBG110AEBRR5

by turning each 82.5°-97.5°
PAINT MARK
DBG110AEBRR3
01-108-36
-CYLINDER BLOCK ASSEMBLY (II) [WL-C, WE-C]
DCF011002000W25
96.1-102.9
{9.B-10, 71-75}
iii
7.8-10.B N·m
{B0--11 0 kgf·cm,
70--95 in·lbf}
7
9
mI
392-441
{40--44,290--325}
7.8-10.B N·m
mI {B0--110 kgf·cm,
70--95 in·lbf}
DBG 11 OBEB001
Oil pump body 8 End plate

2 Control plunger (8ee01-108-38 Rear Cover, End Plate Assembly
Note.)
3 Plunger spring
9 Dual-mass flywheel
4 Plug (8ee01-108-39 Dual-mass Flywheel Assembly
5 Driven gear Note.)
• 6 Oil pump cover 10 8eal plate
• (8ee01-108-38 Oil Pump Cover Assembly Note.) 11 , Timing gear case
r-~~~--------------~--------~----~
7 Rear cover (8ee01-108-39 Timing Gear Case Assembly
(8ee01-108-38 Rear Cover, End Plate Assembly Note.)
Note.) 12 8upply pump
01-108-37
13 Timing gear 17 Supply pump pulley

(See01-108-40 Timing Gear, Supply Pump Gear (See01-108-42 Supply Pump Pulley Assembly
Assembly Note.) Note.)
14 Supply pump gear 18 Seal plate
(See01-108-40 Timing Gear, Supply Pump Gear 19 Crankshaft pulley
Assembly Note.) (See01-108-43 Crankshaft Pulley Assembly Note.)
15 Oil pump
16 Timing gear cover
(See01-108-42 Timing Gear Cover Assembly
Note.)
Oil Pump Cover Assembly Note

Rear Cover, End Plate Assembly Note

hammer
cover and the face of the oil seal.
Rear oil seal press-in amount

0-0.5 mm {0-0.01 in}
+.2:-0.5 mm {0-0.01 in}
t~ REAR OIL SEAL
DBG110BEB059
5. Apply silicone sealant to the rear cover as shown.
Thickness
~2.0-3.0 mm {0.07-0.12 in}
DBG 11 OBEB003
01-108-38
-6. Apply silicone sealant to the rear cover as shown
in the figure.
Thickness
~2.0-3.0 mm {O.07-0.12 in}
7. Install the end plate.
DBG110AEBR94
Dual-mass Flywheel Assembly Note

2. Tighten the bolts in the order shown in the figure.
DBG110BEB051
.. Timing Gear Case Assembly Note

" 1. Install the new O-ring.
2. Apply silicone sealant to the timing gear case as
shown in the figure. Do not apply sealant to the 0-
ring.
Thickness
~2.0-3.0 mm {O.07-0.12 in}
DBG110BEB104

/
DBG110BEB072
01-108-39
-

Timing Gear, Supply Pump Gear Assembly Note
-
1. Put a paint mark on the chip cut gear of the SUPPLY PUMP
supply pump gear. PAINT MARK
GEAR (HELICAL
GEAR)
DBG110AEBR93
2. Put a paint mark on the 10th and 11 th teeth of the CHIP CUT GEAR
helical gear counting clockwise from the chip cut
gear. SUPPLY
PUMP GEAR
VIEWA
PAINT MARK
DBG110BEB141
3. Verify that the 10th and 11 th teeth of supply pump

gear (helical gear) and the teeth of the scissors SCISSORS GEAR HELICAL GEAR
~I
gear are aligned, then put a paint mark on the
scissors gear.
~~10TEETH
~~11 TEETH
PAINT MARK
DBG110BEB103

approximately 30 0 BTOC (13 teeth on the gear).
DBG110AEBR59
01-108-40
6. Align the timing marks. For the supply pump gear, align the timing mark as shown in the figure (View A).
Note
• The helical gears except for the supply pump gear have a punch mark as the timing mark. The timing
mark of each gear can be aligned easily if the paint mark is made on the punch mark.
TIMING MARK (WHITE PAINT)
SUPPLY PUMP GEAR
)~--------------------------------------~~ DBG110BEB078
7. Remove the lock bolt.
DBG110AEBR97
8. Tighten the bolts using the SST.
01-108-41
Timing Gear Cover Assembly Note
hammer.
Front oil seal press-in amount

0.0-0.40 mm {0.0-0.015 in}

0.0-0.40 mm {0.0-0.015 in}
DBGll0BEB012

shown.
Thickness
~2.0-3.0 mm {0.079-0.118 in}
DBGll0BEB071

Supply Pump Pulley Assembly Note

1. Install the supply pump pulley using the SST.
~. I ' I
DBGll0BEB054
01-108-42
MECHANICAL [WL-.C, WE-C]
-
crankshaft Pulley Assembly Note
1. Install the crankshaft pulley using the SST.
DBG110BEB055
CYLINDER BLOCK ASSEMBLY (III) [WL-C, WE-C]

DCF011002000W26
7.85-10.8 N·m
{80-110 kgf·cm,
70-95 in.lbf}

DBG110BEB074
1 Oil pipe 3 Oil pan

(8ee01-108-44 Oil Pipe Assembly Note.) (8ee01-108-44 Oil Pan Assembly Note.)
2 Oil strainer 4 Oil drain plug
01-108-43
:,i!!: :
: '!!
! !
I
IT"·'."'"''·'·''' "
}1
f
Oil Pipe Assembly Note

DBG110BEB076
Oil Pan Assembly Note

1. Apply silicone sealant to the oil pan as shown in
the figure. .-
Thickness
~2.0-3.0 mm {O.07-0.12 in}
2. Tighten the oil pan bolts A as shown in the figure.

A
Caution
sealant from the bolt threads. Tightening o o 0 0 o o

DBG110BEB056
bolt hole damage.
!o'
passes.
)~@i=E
~ OLD SEALANT
CHU0111W004
01-108-44
-
CYLINDER HEAD ASSEMBLY (I) [WL-C, WE-C]
DCF011002000W27
CD
18.6-25.5 {1.9-2.6, 14-18}
DBG110BEB065
1 Water outlet pipe 7 Valve keeper

2 Lower valve spring seat (8ee01-108-46 Valve Keeper Assembly Note.)
3 Valve seal 8 Valve cap "
(8ee01-108-46 Valve 8eal Assembly Note.) 9 Pivot
4 Valve (8ee01-108-46 Pivot Assembly Note.)
5 Valve spring 10 Rocker arm
(8ee 01-108-46 Rocker Arm Assembly Note.)
6 Upper valve spring seat
01-108-45
Valve Seal Assembly Note
1. Tap the SST using a plastic hammer.
\;:'l:::~"";"';''''''':''''---'H- VALVE SEAL
DBGll0BEB008
Valve Keeper Assembly Note

1. Install the valve keeper using the SST.
Pivot Assembly Note

1. Apply adhesive to the thread of the pivot.
Rocker Arm Assembly Note

1. If a new rocker arm is used, set dimension A as
follows.
Dimension A
0.0-4.0 mm {0.0-0.115 in}
DBGll0BWB92
01-108-46
-
:1
CYLINDER HEAD ASSEMBLY (II) [WL-C, WE-C]
DCF011002000W28
7.8-10.8 N·m
{80-110 kgf·cm,
1\
70-S5 in·lbf}
I
~~qb
' ~~ c;]
~~
123-140 {12.6-14.2, SO.8-103.2}

~~S {3.0, 21}
t
17.6-1S.6
{1.8-1.S, 13-14}
CD
7.8-10.8 N·m
{80-110 kgf·cm,
70-S5 in.lbf}
N·m {'kgf.m, ft·lbf}

DBG110BEB026
Cylinder head gasket 5 Camshaft

(See 01-108-48 Cylinder Head Gasket Assembly 6 Camshaft cap upper
Note.) (See 01-108-49 Camshaft Cap Upper Assembly
2 Cylinder head Note.)
(See 01-108-48 Cylinder Head Assembly Note.) 7 Seal plate
3 ECT sensor (See 01-108-50 Seal Plate Assembly Note.)
4 Camshaft cap lower 8 Camshaft pulley
(See 01-108-49 Camshaft Cap Lower Assembly (See 01-108-50 Camshaft Pulley Assembly Note.)
Note.)
01-108-47
Cylinder Head Gasket Assembly Note
1. Measure the piston topping of all the cylinders.
+TOPPING
CYLINDER PISTON
BLOCK
DPEll0ZE1R02

piston topping.
Piston topping (mm {in})
identification mark
0.080-0.190 {0.004-o.007}
--+'
0.135-0.255 {0.006-o.01 O} ,---J IDENTIFICATION MARK
POSITION
0.200-0.310 {0.008-0.012} ~ DPEll0BEBR94

shown in the figure. 16.0 mm
{0.63 in}
Thickness ~,.-t-+
02.0-3.0 mm {0.08-0.11 in} 44.0mm

{1.73 in} ENGINE
39.5mm FRONT
{1.56 in}
~;II--!- 23.5 mm
{0.93 in}
DBGll0BWBR9
Cylinder Head Assembly Note

1. Before installing the cylinder head bolts, inspect their length. (See01-10B-31 BOLT INSPECTION [WL-C, WE-
C].)
3. Tighten the bolts in two or three steps in the order shown in the figure.
Tighten torque
29 N·m {3.0 kgf·m, 21 ft.lbf}

{3.0 kgf·m, 2.1 ft·lbf}.
DBGll0BEB027
I j: 01-108-48
IL I
-
PAINT MARK
by turning each 90°-105° in the sequence
a shown.
" 7. Further tighten each bolt by turning another 90°-
105°.
105°.
9. Apply adhesive to the thread of bolt A.
10. Tighten bolts A.
PAINT MARK
Tighten torque
DBG110AWB311
17.6-19.6 N·m {1.8-1.9 kgf·m, 13-14 ft.lbf}
Camshaft Cap Lower Assembly Note

DBG110BEB105
Camshaft Cap Upper Assembly Note
t 1. Apply adhesive to the front camshaft cap

mounting surfaces as shown in the figure.
2. Tighten the camshaft cap bolts gradually in three
or four steps in the order shown in the figure.
Caution t t - - - 4 ADHESIVE
-Because there is little camshaft thrust
clearance, the camshaft must be held
horizontally while it is installed.
applied to the thrust area, causing burrs
DBG110BWB86
cylinder head journal. To avoid this, the

oil seal.
01-108-49
5. Tap the oil seal lightly into the cylinder head using
~
the SST and a hammer.
cylinder head and the face of the oil seal.
CYLINDER
0.5-1.0 mm {0.02-0.03 in}
Camshaft oil seal press-in amount HEAD
Ii
0.5-1.0 mm {0.020-0.039 in}
HAMMER
OIL SEAL
DPE110ZE1R41
Seal Plate Assembly Note

in the figure.
SEAL PLATE
DBG110BEB041
Camshaft Pulley Assembly Note

1. Install the camshaft pulleys, positioning the knock
pins as shown in the figure. INTAKE EXHAUST
CAMSHAFT KNOCK PIN CAMSHAFT
PULLEY PULLEY
DBG110BWB85
2. Hold the camshaft using a wrench on the cast hexagon.
Caution
CAMSHAFT PULLEY
damage them.
DBG110BEBR17
01-108-50
-
TIMING BELT ASSEMBLY [WL-C, WE-C]
DCF011002000VV29
21-26 {2.2-2.6, 16-19}
") 1.8-1" N·m (80--110 kgl.,m,
_,f;.>4 ~ ,.....,5;".,b"~
1S.6-25.5 {1.9-2.6, 14-1S}
\(a.·
.'1
35-52 {3.5-5.3,
25-3S}
~~
1
6
70-95 in.lbf}
7.S-10.S N·m {SO-110 kgf·cm,

70-95 in'lbf} N·m {kgf'm, tt·lbf}
DBG110BEB046
ICylinder head cover Auto tensioner

(8ee01-10B-52 Timing Belt Assembly Note.)
Injector
01-108-51
MECHANICAL [WL-C, WE-C] .
4 Timing belt 6 Timing belt cover

(See01-108-52 Timing 8elt Assembly Note.) (See 01-108-53 Timing 8elt Cover Assembly
5 Idler Note.) I.fi:
(See01-108-52 Timing 8elt Assembly Note.) Water pump
7
8 Vacuum pump
I"
Cylinder Head Cover Assembly Note

Thickness
02.0-3.0 mm {0.08-0.11 in}
DBG110BWB84

DBG110BEB005
Timing Belt Assembly Note

1. Align the timing marks as shown in the figure. INTAKE
2. Verify that the supply pump attaching bolts and EXHAUST
CAMSHAFT CAMSHAFT
nuts are tightened to the specified torque. This PULLEY PULLEY
must be done to prevent over-tensioning of the
timing belt after it has been installed.
TIMING MARK
TIMING ~@\-SUPPLY PUMP

MARK ~ PULLEY
DBG110BWB97
3. Install the tensioner and hand-tighten lock bolts A

and B.
5. Install the idler.
6. Tighten the lock bolt A.
7. Tighten the lock bolt B.
8. Remove the set pin from the tensioner.
camshaft pully timing marks. If they are not
aligned, remove the timing belt and repeat from
Step 1.
DBG110BWB96
01-108-52
-Timing Belt Cover Assembly Note
1. Tighten the timing belt cover bolts in the order @
DBG110BEB043
01-108-53
TECHNICAL DATA [WL-3]
-01-50A TECHNICAL DATA [WL-3]
ENGINE TECHNICAL DATA [WL-3] .... 01-50A-1
,-----------------------------------------
ENGINE TECHNICAL DATA [WL-3]
DCF015000000W01
Item Specification
X distortion: 0.02 mm {0.0008 in}
Maximum cylinder head distortion Y distortion: 0.05 mm {0.0020 in}
Maximum combustion chamber recession 0.02 mm {0.0008 in}
Maximum combustion chamber projection 0.005 mm {0.0002 in}
Combustion chamber crack Limit: 10mm {0.39 in}
Maximum manifold contact surface distortion 0.05 mm {0.0020 in}
Maximum manifold contact surface grinding 0.15 mm {0.0059 in}
IN: 1.5 mm {0.059 in}
EX: 0.75 mm {0.030 in}
IN: 111.6-112.1 mm {4.394-4.413 in}
Standard valve length EX: 111.5-112.0 mm {4.390-4.409 in}
IN: 111.35 mm {4.384 in}
EX: 111.25 mm {4.380 in}
IN: 6.970-6.985 mm {0.2745-0.2749 in}
EX: 6.965-6.980 mm {0.2743-0.2748 in}
IN: 6.920 mm {0.2724 in}
EX: 6.915 mm {0.2722 in}
Standard valve guide inner diameter 7.025-7.045 mm {0.2766-0.2773 in}
Standard valve guide height 14.0-14.5 mm {0.552-0.570 in}
IN: 1.6-2.2 mm {0.063-0.086 in}
EX: 1.7-2.3 mm {0.067-0.090 in}
IN: 45°
Valve seat angle
EX: 45°
IN: 0.61-1.09 mm {0.025-0.042 in}
EX: 0.71-1.19 mm {0.028-0.046 in}
IN: 1.50 mm {0.059 in}
EX: 1.60 mm {0.063 in}
Valve spring installation pressing force 238-269 N {25-27 kgf, 54-60 Ibf}
Valve spring installation height 35.5 mm {1.40 in}
Maximum valve spring out-of-square 2.0° (1.70mm {0.067 in})
Maximum camshaft runout 0.03 mm {0.0012 in}
IN: 42.400-42.500 mm {1.6692-1.6732 in}'
EX: 42.395-42.495 mm {1.6691-1.6730 in}
IN: 42.050 mm {1.6555 in}
EX: 42.045 mm {1.6711 in}
'"
No.1, No.5: 25.940-25.965 mm {1.0213-1.0222 in}
Standard cam journal diameter
No.2-No.4: 25.910-25.935 mm {1.0201-1.0210 in}
No.1, No.5: 25.890 mm {1.0193 in}
No.2-No.4: 25.860 mm {1.0181 in}
No.1, 5: 0.035-0.081 mm {0.0014-0.0031 in}
No.2-4: 0.065-0.111 mm {0.0026-0.0043 in}
No.1, 5: 0.12 mm {0.0047 in}
No.2-4: 0.15 mm {0.0059 in}
Standard camshaft end play 0.030-0.160 mm {0.0012-O.0062 in}
Maximum camshaft end play 0.20 mm {0.0079 in}
Standard: 93.000-93.022 mm {3.6615-3.6622 in}
Cylinder bore size 0.25 {0.01} oversize: 93.250-93.272 mm {3.6713-3.6721 in}
0.50 {0.02} oversize: 93.500-93.522 mm {3.6811-3.6819 in}
Cylinder bore wear limit 0.15 mm {0.0059 in} .
Oil jet air pressure 137.6-196.4 kPa {1.5-2.0 kgf/cm 2 , 20-28 psi}
01-50A-1
Item Specification
Standard: 92.951-92.977 mm {3.6595-3.6605 in}
Piston diameter 0.25 {0.0098} oversize: 93.186-93.212 mm {3.6688-3.6697 in}
Standard piston clearance

0.50 {0.02} oversize: 93.436-93.462 mm {3.6786-3.6795 in}
0.055-0.073 mm {0.0022-0.0028 in}
~
Maximum piston clearance 0.15 mm {0.0059 in}
Top: 0.06-0.10 mm {0.0024-0.0039 in}
Standard piston ring clearance Second: 0.04-0.08 mm {0.0016-0.0031 in}
Oil: 0.03-0.07 mm {0.0012-0.0027 in}
Maximum piston ring clearance 0.15 mm {0.0059 in}
Top: 0.22-0.32 mm {0.0087-0.0125 in}
Standard piston ring end gap Second: 0.32-0.47 mm {0.0126-0.0185 in}
Oil: 0.22-0.37 mm {0.0087-0.0145 in}
Maximum piston ring end gap 1.0 mm {0.039 in}
Standard piston pin bore diameter 31.997-32.007 mm {1.2598-1.2601 in}
Standard connecting rod small end inner diameter 32.012-32.033 mm {1.2604-1.2611 in}
Standard piston pin diameter 31.994-32.000 mm {1.25961-1.25984 in}
Standard piston pin-to-piston pin bore clearance -0.003-0.013 mm {-0.00011-0.00051 in}
Standard connecting rod small end-to-piston pin
0.012-0.039 mm {0.00048-0.00153 in}
clearance
Maximum crankshaft runout 0.05 mm {0.0020 in}
Standard
No.1, 2, 4, 5: 66.937-66.955 mm {2.6354-2.6360 in}
NO.3: 66.920-66.938 mm {2.6347-2.6353 in}
No.1, 2, 4, 5: 66.687-66.705 mm {2.6255-2.6261 in}
NO.3: 66.670-66.688 mm {2.6248-2.6255 in}
Main journal diameter
No.1, 2, 4, 5: 66.437-66.455 mm {2.6157-2.6163 in}
NO.3: 66.420-66.438 mm {2.6150-2.6156 in}
No.1, 2, 4, 5: 66.187-66.205 mm {2.6058-2.6064 in}
4
NO.3: 66.170-66.188 mm {2.6052-2.6058 in}
Main journal wear limit 0.05 mm {0.0020 in}
Main journal out-ot-round 0.03 mm {0.0012 in}
Standard: 54.940-54.955 mm {2.1630-2.1635 in}
0.25 {0.01} undersize: 54.690-54.705 mm {2.1532-2.1537 in}
Crank pin diameter
0.50 {0.02} undersize: 54.440-54.455 mm {2.1434-2.1438 in}
0.75 {0.03} undersize: 54.190-54.205 mm {2.1335-2.134 in}
Crank pin wear limit 0.05 mm {0.0020 in}
Crank pin out-ot-round 0.03 mm {0.0012 in}
No.1, 2, 4, 5: 0.027-0.046 mm {0.0011-0.0018 in}
No.3: 0.044-0.063 mm {0.0018-O.0025 in}
Maximum main journal clearance 0.08 mm {0.0031 in}
Standard: 2.006-2.021 mm {0.0790-0.0795 in}
0.25 {0.01} undersize: 2.124-2.134 mm {0.0837-0.0840 in}
0.50 {0.02} undersize: 2.249-2.259 mm {0.0886-0.0889 in}
0.75 {0.03} undersize: 2.374-2.384 mm {0.0935-0.0938 in}
Standard crankshaft end play 0.040-0.282 mm {0.0016-0.0111 in}
Maximum crankshaft end play 0.3 mm {0.012 in}
Standard: 2.454-2.506 mm {0.0967-0.0986 in}
0.35 {0.014} oversize: 2.629-2.681 mm {0.1036-0.1055 in}
Maximum connecting rod bending 0.075 mm {0.0030 in} /50 mm {2.0 in}
Maximum connecting rod distortion 0.18 mm {0.0071 in} /50 mm {2.0 in}
Connecting rod center-to-center distance 151.96-152.04 mm {5.9827-5.9858 in}
Standard connecting rod bolt length 67.5-68.5 mm {2.66-2.69 in}
Maximum connecting rod bolt length 69 mm {2.7 in}
Standard connecting rod oil clearance 0.025-0.052 mm {0.001 0-0.0020 in}
Maximum connecting rod oil clearance 0.08 mm {0.0031 in}
01-50A-2
..
~~
•
--
Item Specification
- Standard: 1.507-1.516 mm {0.0594-0.0596 in}
0.25 {0.01} undersize: 1.624-1.634 mm {0.0640-0.0643 in}
. Connecting rod bearing thickness
0.50 {0.02} undersize: 1.749-1.759 mm {0.0689-0.0692 in}
0.75 {0.03} undersize: 1.874-1.884 mm {0.0738-0.0741 in}
Standard connecting rod side clearance 0.110-0.262 mm {0.0044-0.01 03 in}
Maximum connecting rod side clearance 0.35 mm {0.014 in}
Bolt head mark W
Bolt head mark N
Standard tensioner spring length 63.0 mm {2.48 in}
IN: 0.05-0.15 mm {0.0020-0.0059 in}
Valve clearance (engine cold)
EX: 0.15-0.25 mm {0.0060-0.0098 in}
Fuel injection pump plunger adjustment value 0.95-1.05 mm {0.038-0.041 in}
Standard oil pump tip clearance 0.10-0.19 mm {0.004Q-0.0074 in}
Maximum oil pump tip clearance 0.20 mm {0.0079 in}
Standard oil pump side clearance 0.04-0.09 mm {0.0016-0.0035 in}
Maximum oil pump side clearance 0.15 mm {0.0059 in}
Standard plunger spring length 43.8 mm {1.72 in}
Front oil seal press-in amount 0-0.4 mm {0-0.01 in}
Fuel injection pump oil seal press-in amount 0-0.4 mm {0-0.01 in}
Camshaft oil seal press-in amount 0.5-1.0 mm {0.02-0.03 in}
"
01-50A-3
r
·,··,.·il
1
.• ,. '.•. . i
,'. .,1'1
.
'I'i
!
. ,
!
i
TECHNICAL DATA [WL-C, WE-C]
-
01-508 TECHNICAL DATA [WL-C, WE-C]
t ENGINE TECHNICAL DATA
[WL-C, WE-C] .................... 01-508-1
ENGINE TECHNICAL DATA [WL-C, WE-C]

DCF015000000W02
Item Specification
X distortion: 0.02 mm {0.0008 in} max.
Y distortion: 0.05 mm {0.0020 in} max.
Maximum manifold contact surface distortion 0.05 mm {0.002 in} max.
Maximum manifold contact surface grinding 0.15 mm {0.0059 in} max.
IN: 1.55-1.85 mm {0.061-0.072 in}
EX: 1.80-2.10 mm {0.070-0.082 in}
IN: 111.65-112.25 mm {4.394-4.413 in}
EX: 111.6-112.2 mm {4.390-4.409 in}
IN: 111.50 mm {4.390 in}
EX: 111.45 mm {4.388 in}
IN: 5.970-5.985 mm {0.2350-0.2356 in}
EX: 5.965-5.980 mm {0.2348-0.2354 in}
IN: 5.920 mm {0.2330 in}
EX: 5.915 mm {0.2328 in}
Standard valve guide inner diameter 6.025-6.045 mm {0.2372-0.2379 in}
IN: 15.0-15.5 mm {0.59-0.61 in}
EX: 17.0-17.5 mm {0.67-0.69 in}
IN: 15.0-15.5 mm {0.59-0.61 in}
EX: 17.0-17.5 mm {0.67-0.68 in}
Standard valve seat contact width 1.3-1.9 mm {0.052-0.074 in}
IN: 45°
Valve seat angle
EX: 45°
IN: 0.79-1.27 mm {0.039-0.050 in}
EX: 0.84-1.32 mm {0.033-0.051 in}
IN: 1.68 mm {0.066 in}
EX: 1.73 mm {0.062 in}
Valve spring installation pressing force 172.9-195.6 N {15.67-17.74 kgf, 34.48.,.-39.02Ibf}
Valve spring installation height 39.0 mm {1.53 in}
Maximum valve spring out-of-square 2.0° (1.60mm {0.062 in})
Maximum camshaft runout 0.03 mm {0.001 in} max.
IN: 42.067-42.167 mm {1.6561-1.6601 in},
EX: 41.949-42.049 mm {1.6515-1.6554 in}
IN: 41.717 mm {1.6424 in}
EX: 41.599 mm {1.6377 in}
No.1: 31.940-31.965 mm {1.2575-1.2582 in}
Standard cam journal diameter No.2-No.4: 25.910-25.935 mm {1.0201-1.0210 in}
No.5: 25.940-25.965 mm {1.0212-1.0222 in}
No.1: 31.890 mm {1.2555 in}
Minimum cam journal diameter No.2-No.4: 25.860 mm {1.0181 in}
No.5: 25.890 mm {1.0193 in}
No.1: 0.035-0.081 mm {0.0014-0.0031 in}
Standard camshaft clearance NO.2-4: 0.065-0.111 mm {0.0026-0.0043 in}
No.5: 0.056-0.081 mm {0.0014-0.0031 in}
No.1: 0.12 mm {0.0047 in}
Maximum camshaft clearance NO.2-4: 0.15 mm {0.0059 in}
No.5: 0.16 mm {0.0063 in}
Standard camshaft end play 0.030-0.160 mm {0.0012-O.0062 in}
Maximum camshaft end play 0.20 mm {0.0078 in}
Standard: 93.000-93.022 mm {3.6615-3.6622 in}
Cylinder bore size [WL-C] 0.25 {0.01} oversize: 93.250-93.272 mm {3.6713-3.6721 in}
0.50 {0.02} oversize: 93.500-93.522 mm {3.6811-3.6819 in}
01-508-1
96.000-96.022 mm {3.6615-3.6622 in}

Cylinder bore size [WE-C] 0.25 {0.01} oversize: 96.250-96.272 mm {3.7893-3.7902 in}
0.50 {0.02} oversize: 96.500-96.522 mm {3.7992-3.8000 in}
Oil jet air pressure 137.6-196.4 kPa {1.4-2.0 kgf/cm 2 , 20-28 psi}
Standard: 92.918-92.944 mm {3.6582-3.6592 in}
Piston diameter [WL-C] 0.25 {0.010} oversize: 93.153-93.179 mm {3.6675-3.6684 in}
0.50 {0.020} oversize: 93.403-93.429 mm {3.6773-3.6782 in}
Standard: 95.918-95.944 mm {3.7763-3.7773 in}
Piston diameter [WE-C] 0.25 {0.010} oversize: 96.153-96.179 mm {3.7856-3.7865 in}
0.50 {0.020} oversize: 96.403-96.429 mm {3.7954-3.7964 in}
Top: 0.06-0.10 mm {0.0024-0.0039 in}

Standard piston ring clearance [WL-C] Second: 0.06-0.08 mm {0.0024-0.0031 in}
Oil: 0.02-0.06 mm {0.0012-0.0023 in}
Top: 0.06-0.10 mm {0.0024-0.0039 in}
Standard piston ring clearance [WE-C] Second: 0.04-0.08 mm {0.0016-0.0031 in}
Oil: 0.02-0.06 mm {0.0008-0.0023 in}
Top: 0.22-0.32 mm {0.0087-0.0125 in}

Standard piston ring end gap [WL-C] Second: 0.49-0.64 mm {0.0193-0.0251 in}
Oil: 0.22-0.52 mm {0.0087-0.0204 in}
Top: 0.23-0.33 mm {0.0091-0.0129 in}
Standard piston ring end gap [WE-C] Second: 0.50-0.65 mm {0.0197-0.0255 in}
Oil: 0.22-0.52 mm {0.0087-0.0204 in}
0.012-0.039 mm {0.00048-0.0015 in}
Standard: 66.937-66.955 mm {2.6354-2.6360 in}

0.25 {0.01 O} undersize: 66.687-66.705 mm {2.6255-2.6261 in}
Main journal diameter [No.1 ,2,4,5]
0.50 {0.020} undersize: 66.437-66.455 mm {2.6157-2.6163 in}
0.75 {0.030} undersize: 66.187-66.205 mm {2.6058-2.6064 in}
Standard: 66.920-66.938 mm {2.6347-2.6353 in}
0.25 {0.01 O} undersize: 66.670-66.688 mm {2.6367-2.6373 in}
Main journal diameter [No.3]
0.50 {0.020} undersize: 66.420-66.438 mm {2.6150-2.6156 in}
0.75 {0.030} undersize: 66.170-66.188 mm {2.6052-2.6058 in}
Standard: 54.940-54.955 mm {2.1630-2.1635 in}

0.25 {0.010} undersize: 54.690-54.705 mm {2.1532-2.1537 in}
Crank pin diameter [WL-C]
0.50 {0.020} undersize: 54.440-54.455 mm {2.1434-2.1438 in}
0.75 {0.030} undersize: 54.190-54.205 mm {2.1335-2.1340 in}
Standard: 56.940-56.955 mm {2.2417-2.2423 in}
0.25 {0.010} undersize: 56.690-56.705 mm {2.2318-2.2324 in}
Crank pin diameter [WE-C]
0.50 {0.020} undersize: 56.440-56.455 mm {2.2220-2.2226 in}
0.75 {0.030} undersize: 56.190-56.205 mm {2.2122-2.2128 in}
No.1, 2, 4, 5: 0.027-0.045 mm {0.001 0-0.0017 in}

No.3: 0.044-0.062 mm {0.0017-0.0024 in}
01-508-2
- Item Specification
Standard: 2.006-2.021 mm {0.0789-0.0794 in}
J Main bearing thickness
0.25 {0.010} undersize: 2.124-2.134 mm {0.0836-0.0838 in}
0.50 {0.020} undersize: 2.249-2.259 mm {0.0885-0.0888 in}
0.75 {0.030} undersize: 2.374-2.384 mm {0.0934-0.0937 in}
Standard crankshaft end play 0.040-0.282 mm {0.0016-O.0111 in}
Maximum crankshaft end play 0.3 mm {0.01 in}
Standard: 2.455-2.505 mm {0.0967-0.986 in}
Thrust bearing thickness 0.35 {0.01 O} oversize: 2.630-2.680 mm {0.1 036-0.1 055 in}
Connecting rod bending 0.075 mm {0.0030 in} max.l50 mm {2.0 in}
Connecting rod distortion 0.18 mm {0.0070 in} max.l50 mm {1.968 in}
Connecting rod center-to-center distance [WL-C] 162.96-163.04 mm {5.983-5.986 in}
Connecting rod center-to-center distance [WE-C] 157.96-158.04 mm {5.983-5.986 in}
Standard connecting rod oil clearance 0.025-0.052 mm {0.0009-0.0020 in}
Maximum connecting rod oil clearance 0.08 mm {0.003 in}
Standard: 1.507-1.516 mm {0.0592-0.0595 in}
0.25 {0.010} undersize: 1.624-1.634 mm {0.0638-0.0642 in}
Connecting rod bearing thickness 0.50 {0.020} undersize: 1.749-1.759 mm {0.0687-0.0691 in}
0.75 {0.030} undersize: 1.874-1.884 mm {0.0737-0.0740 in}
Standard connecting rod side clearance 0.110-0.262 mm {0.0043-0.01 03 in}
Maximum connecting rod side clearance 0.35 mm {0.014 in}
Balance shaft Standard end play 0.04-0.16 mm {0.002-0.006 in}
Front: 41.945-41.960 mm {1.6514-1.6519 in}
Standard diameter Center: 39.945-39.960 mm {1.5727-1.5732 in}
Rear: 37.975-37.990 mm {1.4951-1.4956 in}
Front, rear: 0.050-0.115 mm {0.0020-0.0045 in}
Standard clearance
Center: 0.080-0.145 mm {0.0032-0.0057 in}
Bolt head mark W
t Maximum length: 102.5 mm {4.035 in}
Bolt head mark N
Cylinder head bolt length Standard length: 113.2-113.8 mm {4.457-4.480 in}
Bolt head mark I
Connecting rod cap bolt length
IN: 0.10-0.16 mm {0.0040-0.0062 in}
EX: 0.17-0.23 mm {0.0067-0.0090 in}
IN: 0.10-0.16 mm {0.0040-0.0062 in}
EX: 0.17-0.23 mm {0.0067-0.0090 in}
Standard oil pump tip clearance 0.10-0.19 mm {0.004G-0.0074 in}
Front oil seal press-in amount 0.0-0.40 mm {0.0--0.015 in}
Fuel injection pump oil seal press-in amount 0.0-0.40 mm {0.0-0.015 in}
Camshaft oil seal press-in amount 0.5-1.0 mm {0.020-O.039 in}
01-508-3
SERVICE TOOLS [WL-3]
-
01-60A SERVICE TOOLS [WL-3]
ENGINE [WL-3] . ................... 01-60A-1
t------------------------------------------
ENGINE [WL-3]
DCF016000000W01
1: Mazda SST number
2: Global SST number
Example
1:49 UN30 3050
2:303-050
Engine lifting
brackets
1:49 0107 680A 1:49 L010 1AO 1:49 0636 100B

2:- 2:- 2:-
~ ~
Engine stand Engine hanger
set
1:49 B012 OA2 1:498120170 1:49 B012 015

2:- 2:- 2:-
~3
Pivot Valve seal Installer
~
remover (Part of 49 B012
OA3)
1:498010001 1 :49 E011 1AO 1:498120 215B

2:- 2:- 2:-
Oil seal installer Ring gear brake Pulley puller

set
1:49 8011 103 1 :498010301 1 :49 F027 009
e
2:- 2:- 2:-
Oil seal installer Oil seal installer Oil seal installer
1:49 G011 001 1 :49 L012 001 1:49 L012 002A

2:- 2:- 2:-
~
Piston pin Installer Body
replacer (Part of 49 L012
,
(Part of 49 L012
OAOB) OAOB)
1:49 L012 005 1 :49 L012 003A 1 :49 L012 004A

2:- 2:- 2:-
® ~
8pacer Installer Nut
(Part of 49 L012 (Part of 49 L012 (Part of 49 L012
OAOB) OAOB) OAOB)
01-60A-1
SERVICE TOOLS [WL-3]
1:49 UN30 3050 1:49 L017 5AO 1:499140074
-
2:303-050 2:- 2:-
Engine lifting Support hanger Cam lift
brackets measuring
device
01-60A-2
SERVICE TOOLS [WL-C, WE-C]
-01-608 SERVICE TOOLS [WL-C, WE-C]
J ENGINE SERVICE TOOLS
[WL-C, WE-C] .................... 01-608-1
ENGINE SERVICE TOOLS [WL-C, WE-C]

DCF016000000W02
1: Mazda SST number
Example
1:49 UN30 3050
2:303-050
Engine lifting
brackets
..
1:49 0107 680A 1:49 L010 1AO 1 :49 0636 1008
2:- 2:- 2:-
Engine stand Engine stand

~oJ
°0 :
0
ftp
Valve spring
hanger set
~-, &.',
-"~
lifter arm
1:4980120A2 1:49 8120 170 1:49 F027 009
e
2:- 2:- 2:-
t ~
Pivot Valve seal Oil seal installdr
remover
1:49 8Q10 001 1 :49 E011 1AO 1 :4981202158

2:- 2:- 2:-
~
Oil seal installer Ring gear brake Pulley puller
set
1:49 8011 103 1 :49 8010 301 1 :49 UN30 3050

2:- 2:- 2:-
~~
Oil seal installer Oil seal installer Engine lifting
brackets
1:49 G011 001 1:498012015 1:49 L017 5AO

2:- 2:- 2:-
~
Piston pin Valve guide 8upport hanger
replacer remover and
installer
01-608-1
1:498012016
2:-
Valve seal
installer
01-608-2
- DRIVELINE/AXLE 03
SECTION
ta------------------------------------
TRANSFER . . . . . . . . . . . . . . . 03-16
TECHNICAL DATA ......... 03-50
SERVICE TOOLS ........... 03-60
03-16 TRANSFER
TRANSFER CLEANING ............. 03-16-1 TRANSFER ASSEMBLy ............. 03-16-8
TRANSFER DiSASSEMBLy .......... 03-16-2
TRANSFER CLEANING
DCF031600000W01
Cleaning Precautions
1. Clean the surface of the transfer using steam and cleaning fluids when disassembly.
Warning
• Always wear safety glasses when using compressed air since the foreign material could be blown
by the compression air and damage your eyes.
2. Clean removed components with cleaning fluids and use compressed air to blow off the oil. Clean the oil holes
and passages with compressed air.
03-16-1
TRANSFER DISASS TRANS FE
Before ServO
Ice Prec
EMBLY
.
R
• a prevent fa . autlons
li
environment reIgn material from .
• Inspect Ihe each
. entering th e Iransfer' pertorm dis -....;
Transfer Disasse part while d'lSassembling. assembly and servicin . "",",,"00",,,,,,
1. Disassembl e mbly
.n the order sh . g .n a clean ' du sl·free
own In the figure.
601mB
69
----- DBG316BMB026
03-16-2
TRANSFER
34 Retaining ring
35 H/L clutch hub
36 Low gear
37 Needle bearing
38 Retaining ring
39 Retaining ring
Mainshaft center bearing
40 (See 03-16-7 Mainshaft Center Bearing
Disassembly Note.)
41 Mainshaft
42 Needle bearing
43 Retaining bolt
44 Spring
45 Steel ball
46 2W/4W shift rod
47 2W/4W shift end
48 Interlock pin
49 Snap ring
Mainshaft rear bearing
15 (See 03-16-5 Mainshaft Rear Bearing Disassembly 50 H/L shift rod
Note.) 51 Snap ring
2W/4W clutch hub 52 Plain washer
16 (See 03-16-5 2W/4W Clutch Hub Disassembly 53 Spring
Note.) 54 Plunger
55 H/L shift fork
56 H/L hub sleeve
57 Adjustment shim
58 Countershaft
t~~~--------------~ 59
Countershaft front bearing (front case side)
(See 03-16-7 Countershaft Bearing Disassembly
Note.)
Chain Countershaft rear bearing (center case side)
24 (See 03-16-6 Chain, Front Drive Shaft and 60 (See 03-16-7 Countershaft Bearing Disassembly
Sprocket Disassembly Note.) Note.)
Front drive shaft 61 Baffle plate
25 (See 03-16-6 Chain, Front Drive Shaft and 62 Retaining bolt
Sprocket Disassembly Note.) 63 Retaining ring
Front drive shaft bearing (center case side) Maindrive gear bearing
26 (See 03-16-6 Front Drive Shaft Bearing . 64 (See 03-16-7 Maindrive Gear Bearing DJsassembly
UlsaSE;errlDlV Note.)
Note.)
Front drive shaft bearing (rear case side) 65 Retainer
27 (See 03-16-6 Front Drive Shaft Bearing
Disassembly Note.) 66 Maindrive gear
Sprocket 67 Oil seal (control rod)
28 (See 03-16-6 Chain, Front Drive Shaft and 68 Oil seal (front case)
Sprocket Disassembly Note.) 69 Front case
03-16-3
TRANSFER
Companion Flange Disassembly Note
-
1. Hold the companion flange using the SST.
Center case side
DBG316BMB0Q3
Rear case side
2. Remove the locknut.

3. Remove the companion flange using the SST.
Center case side
Rear case side
03-16-4
TRANSFER
(Rear Case) Disassembly Note
~,(;l,Clm'[)VI:j the oil seal (rear case) using a flathead
",..r,r:!W(mVI~r as shown in the figure.
Oil Seal (Center Case) Disassembly Note

1. Remove the oil seal (center case) using a
flathead screwdriver as shown in the figure.
DBG316BMB040
t Mainshaft
, Rear Bearing Disassembly Note
1. Remove the mainshaft rear bearing using the
SSTs.
DBG316BMB005
2W/4W Clutch Hub Disassembly Note

1. Remove the 2W/4W clutch hub using the SSTs.
DBG316BMB006
03-16-5
TRANSFER
Chain, Front Drive Shaft and Sprocket Disassembly Note
-
1. Remove the front drive shaft using the plastic r--------------------_
hammer.
DBG316BMB042
2. Remove the chain, front drive shaft and sprocket

as a single unit.
Front Drive Shaft Bearing Disassembly Note

1. Remove the front drive shaft bearing using the SSTs and press.
Center case side
:I. II
DBG316BMB007
Rear case side
DBG316BMB008
03-16-6
J
TRANSFER
-Mainshaft Center Bearing Disassembly Note
1. Remove the mainshaft front bearing using the
press.
DBG316BMB012
Countershaft Bearing Disassembly Note

1. Remove the countershaft bearing using the SSTs and press.
Front case side
t Center case side

DBG316BMB010
DBG316BMB011
Maindrive Gear Bearing Disassembly Note

1. Remove the maindrive gear bearing using the
SST, press and steel plate.
Note STEEL PLATE

• Steel plate height: 10 mm {O.39 in} or more.
l' I • ,
DBG316BMB009
03-16-7
TRANSFER
Oil Seal (Control Rod) Disassembly Note
-
1. Remove the oil seal (control rod) using a flathead
screwdriver as shown in the figure.
DBG316BMB043
Oil Seal (Front Case) Disassembly Note

1. Remove the oil seal (front case) using a flathead
screwdriver as shown in the figure.
DBG316BMB041
TRANSFER ASSEMBLY
DCF031600000W03
Before Service Precautions •
• Assemble with bare hands or using vinyl gloves. To prevent foreign material from entering the transfer, do not ..
use cotton work gloves or a rag.
• Apply sufficient gear oil to the sliding surfaces and O-rings, and be careful not to damage when assembling.
• Replace the transfer with a new one if the case alignment surface is damaged. Be careful not to damage it
since it may cause oil leakage.
• When installing silicone sealant, clean off the old sealant adhering to the sealing area and clean the sealing
area with cleaning fluids.
• After installing a seal, leave the parts alone for 2 h or more. Do not add oil or operate the vehicle during this
time.
03-16-8
TRANSFER
J[ransfer Assembly
15-19--1
{1.6-1.9, Ci.!lI
'~W ~
~Aro
~
______ 1~1~15.7-21.6
{1.61-220
1 I ~~;::-___
_
11.6-15·.9}'
. N·m {kgf.m, ft·lbf}
s control rod) DBG316BMB027

[ Front case 011 seal (
(_-'--_
ee 03-16- 11 Oil Seal (control rod) A
_ _ I Note.)
_ _ _ _:..-=::ssEsembl
y
03-16-9
TRANSFER
,
Oil seal (front case) Sprocket
-
3 (See 03-16-11 Oil Seal (front case) Assembly 41 (See 03-16-14 Chain, Front Drive Shaft and
Note.} Sprocket Assembly Note.)
4 Maindrive gear Front drive shaft bearing (rear case side)
5 Retainer 42 (See 03-16-15 Front Drive Shaft Bearing Assembly
Note.)
Maindrive gear bearing
6 (See 03-16-11 Maindrive Gear Bearing Assembly Front drive shaft bearing (center case side)
Note.) 43 (See 03-16-15 Front Drive Shaft Bearing Assembly
Note.)
Retaining ring
7 (See 03-16-11 Maindrive Gear Bearing Assembly Front drive shaft
Note.) 44 (See 03-16-14 Chain, Front Drive Shaft and
Sprocket Assembly Note.)
8 Retaining bolt
Chain
9 Baffle plate 45 (See 03-16-14 Chain, Front Drive Shaft and
Countershaft rear bearing (center case side) Sprocket Assembly Note.)
10 (See 03-16-12 Countershaft Bearing Assembly Needle bearing
Note.) 46 (See 03-16-14 Chain, Front Drive Shaft and
Countershaft front bearing (front case side) Sprocket Assembly Note.)
11 (See 03-16-12 Countershaft Bearing Assembly 47 Snap ring
Note.)
48 Collar
Countershaft
12 49 Spring
(See 03-16-12 Countershaft Assembly Note.)
Adjustment shim 50 2W/4W hub sleeve
.13 (See 03-16-12 Countershaft Assembly Note.) 2W/4W shift fork
51
14 H/L hub sleeve 52 Spacer
15 H/L shift fork 53 Snap ring
16 Plunger 2W/4W clutch hub
17 Spring 54 (See 03-16-15 2W/4W Clutch Hub Assembly
Note.)
18 Plain washer
19 Snap ring 55 (See 03-16-16 Mainshaft Rear Bearing Assembly
20 H/L shift rod Note.)
21 Snap ring 56 Speed drive gear
22 Interlock pin Rear case
57
23 2W/4W shift end (See 03-16-16 Rear Case Assembly Note.)
24 2W/4W shift rod Oil seal (center case)
Steel ball 58 (See 03-16-16 Oil Seal (center case) Assembly
25
Note.}
26 Spring
59 Companion flange (center case side)
27 Retaining bolt
Oil seal (rear case)
28 Needle bearing 60 (See 03-16-17 Oil Seal (rear case) Assembly
Mainshaft Note.}
29 (See 03-16-13 Mainshaft and Mainshaft Center 61 Companion flange (rear case side)
Bearing Assembly Note.)
62 Control rod
Mainshaft center bearing
(See 03-16-13 Mainshaft and Mainshaft Center 63 Control rod end
30
Bearing Assembly Note.) 64 Guide plate
31 Retaining ring 65 Reverse gate lever
Retaining ring 66 Reverse gate spring
32 (See 03-16-13 Mainshaft and Mainshaft Center 67 Spacer
Bearing Assembly Note.) 68 E-ring
33 Needle bearing Control case
34 Low gear 69
(See 03-16-17 Control Case Assembly Note.)
35 H/L clutch hub
36 Retaining ring
Center case
37
(See 03-16-13 Center Case Assembly Note.)
Oil passage
38
(See 03-16-14 Oil Passage Assembly Note.)
Oil catcher
39
(See 03-16-14 Oil Catcher Assembly Note.)
40 Center bearing retainer
03-16-10
-. Oil Seal (control rod) Assembly Note
TRANSFER
t, ·
caution
Assemble the oil seal being careful not to assemble it in the incorrect direction.
1. Apply specified grease to the lip of a new oil seal.

2. Install the oil seal (control rod) using the SST.
Installation depth A: 0 mm {O in}
..
DBG316BMB030
Oil Seal (front case) Assembly Note

2. Install the oil seal (front case) using the SST.
Installation depth A: 2.4-3.0 mm {0.095-

0.118in} " I
• DBG316BMB013
Maindrive Gear Bearing Assembly Note

1. Assemble the maindrive gear bearing using the
SST and press.
2. Install the retaining ring.
DBG316BMB021
03-16-11
TRANSFER
3. Measure the clearance between the retaining ring
-
and groove of the maindrive gear. RETAINING RING
• If not within the specification, adjust by
choosing the proper retaining ring.
Maindrive gear bearing end play

0-0.15 mm {0.0-0.0059 in} MAINDRIVE GEAR END PLAY
Maindrive gear bearing retaining ring

Thickness (mm {in})
2.60 {0.1 02}
2.67 {0.105} DBG316BMB033
2.74 {0.108}
Countershaft Bearing Assembly Note

1. Assemble the countershaft bearing using the SSTs and press.
Front case side
DBG316BMB019
Center case side
~. ~ I
~. I , •
DBG316BMB020
Countershaft Assembly Note

1. Assemble the countershaft to the front case.
2. Measure the depth A as shown in the figure.
3. Select the correct countershaft adjustment shim A
thickness.
Countershaft adjustment shim selective chart

Dimension A (mm {in}) Shim thickness (mm {in})
25.0-25.1
0.5 {0.020}
{0.985-0.988}
25.1-25.2
0.4 {0.016}
{0.989-0.992}
25.2-25.3
0.3 {0.012}
{0.993-0.996} DBG316BMB032
25.3-25.4
0.2 {0.008}
{0.997-1.000}
25.4-25.5
0.1 {0.004}
{1.000-1.003}
25.5-25.6
{1.004-1.007}
-
4. Install the adjustment shim.

03-16-12
TRANSFER
-Mainshaft and Mainshaft Center Bearing Assembly Note
1. Assemble the mainshaft center bearing using the r----------------------,
SST and press.
DBG316BMB018
2. Measure the clearance between the retaining ring MAINSHAFT CENTER BEARING
and groove of the mainshaft.
• If not within the specification, adjust by RETAINING RING
MAINSHAFT
Mainshaft center bearing end play

0-0.15 mm {0.0-0.0059 in}
Mainshaft center bearing retaining ring

Thickness (mm {in}) o MAINSHAFT CENTER BEARING
END PLAY
3.1 {O.122}
3.2 {O.126} DBG316BMB031
3.3 {O.130}
3. Assemble the mainshaft to the center case using the plastic hammer.
Center Case Assembly Note

1. Apply sealant to the contact surfaces of the front
case and center case as shown in the figure.
DBG316BMB028
2. Assemble the center case.
Bolt length (measured from below the head)

43 mm {1.69 in}
DBG316BMB038
03-16-13
TRANSFER
Oil Passage Assembly Note
1. Assemble the oil passage to the center case.
Note
• Align the oil passage of the center case
groove as shown in the figure.
OIL PASSAGE
CENTER CASE
DBG316BMB035
Oil Catcher Assembly Note

1. Align the oil catcher groove as shown in the
figure.
DBG316BMB016 t
3. Install the oil catcher using the SST.
DBG316BMB017
Chain, Front Drive Shaft and Sprocket Assembly Note

1. Assemble the chain, front drive shaft and sprocket
as a single unit.
Note
• Assemble the front drive shaft using the
plastic hammer.
DBG316BMB036
03-16-14
TRANSFER
-
2. Install the needle bearings while turning the
mainshaft.
Front Drive Shaft Bearing Assembly Note

1. Assemble the front drive shaft bearing using the SSTs and press.
Center case side
DBG316BMB023
Rear case side
DBG316BMB022
2W/4W Clutch Hub Assembly Note

1. Assemble the 2W/4W clutch hub using the SST.
DBG316BMB024
03-16-15
TRANSFER
Mainshaft Rear Bearing Assembly Note
1. Assemble the mainshaft rear bearing using the
SST.
Rear Case Assembly Note

1. Apply sealant to the contact surfaces of the center
case and rear case as shown in the figure.
DBG316BMB029
2. Assemble the rear case.
Bolt length (measured from below the head)

A: 58 mm {2.28 in}
B: 113 mm {4.45 in}
DBG316BMB034
Oil Seal (center case) Assembly Note

2. Install the oil seal (center case) using the SST.
DBG316BMB014
03-16-16
TRANSFER
-
Oil Seal (rear case) Assembly Note
2. Install the oil seal (rear case) using the SST.
, Installation depth A: 6.7-7.3 mm {0.27-

0.28 in}
Control Case Assembly Note

1. Apply sealant to the contact surfaces of the
control case and transfer case as shown in the
figure.
2. Install the control case to the transfer case. m:!!.1S1
DBG511BMB021
03-16-17
TRANSFER [5R55S]
TRANSFER CASE CLEANING TRANSFER CASE ASSEMBLY
[5R55S] ......................... 03-16-1 [5R55S] . ........................ . 03-16-14
TRANSFER CASE DISASSEMBLY TRANSFER CASE INSPECTION
[5R55S] ......................... 03-16-2 [5R55S] . ........................ . 03-16-26
TRANSFER CASE CLEANING[5R55S]

id0316c1501000
Note
• Before cleaning, check the magnet for the presence of metal particles which indicate internal chipping of
the transfer case.
1. Using a cleaning solvent, clean the old oil and dirt deposits.
2. After cleaning dry the parts with low pressure (138 kPa {1.41 kgf/cm 2 , 20 psi maximum}) compressed air.
3. Lubricate the ball bearings and needle bearing with oil. Protect lubricated bearings from dust.
03-16-1
TRANSFER!.!:[5~R5~5S~]_ __
TRANSFER CASE DISAS SEMBLY[5R55S]

id0316c1501100
Exploded
_ _ _ _~
I
V"ew .
Center transfer case
==___
1 . 5 Oil seal component
2 Dowel pm --=- "Center transfer case
3 Bearing 6 Front transfer case
4 Snap ring 78 Dowel~ ;::;::-.
03-16-2
TRANSFER [5R55S]
-
9 Snap ring 48 Snap ring
10 Front transfer case component 49 Drive sprocket
11 Clip 50 Drive chain
12 Bolt 51 Driven sprocket
13 Input shaft component 52 Snap ring
14 Input shaft 53 Spacer
15 Needle bearing 54 Lower output shaft
16 Bushing 55 Front output flange component
17 Thrust washer 56 Front output flange
18 Planetary gear component 57 Deflector
19 Sun gear 58 Oil seal
20 Thrust plate 59 Washer
21 Snap ring A 60 Locknut
22 Ball bearing 61 Rear transfer case component
23 Snap ring B 62 Rear transfer case
24 Reduction shift fork component 63 Needle bearing
25 Reduction shift fork 64 Sleeve
26 Reduction shift fork facing 65 Seal
27 Lockup shift fork component 66 Snubber
28 Lockup shift fork 67 Bolt
29 Lockup shift fork facing 68 Clutch coil
30 Spring 69 Nut
31 Spacer 70 Clutch housing
32 Cam 71 Breather pipe
33 Shift shaft 72 Speed sensor component
34 Rail shift 73 Bracket
35 Return spring 74 Bolt
36 Output shaft and gerotor pump component 75 Spacer
37 Output shaft component 76 Rear companion flange component
38 Gerotor pump component 77 Rear companion flange
39 Reduction hub 78 Oil plug
40 Pump hose 79 Motor component
41 Hose clamp 80 Bracket
42 Oil strainer 81 Terminal connector
43 Magnet 82 Clip
44 Lockup component 83 Bracket
45 Lockup hub 84 Clip
46 Spring 85 Bolt
47 Lockup collar 86 Bolt
03-16-3
TRANSFER [5R55S]
Disassembly Procedure
-
1. Using the SST, set the transfer case as shown in
the figure.
b5r5za00000426
2. Secure the rear companion flange component

using the SST.
3. Remove the nut and washer.
NUT-~
~
WASHER
4. Remove the rear companion flange using the

pulley.
REAR
COMPANION
FLANGE
5. Remove the deflector from the flange.
@---DEFLECTOR
'>----FLANGE
arnffv00000616
03-16-4
TRANSFER [5R55S]
-6. Remove the oil seal from the output shaft.
OILSEAL~
b5r5za00000456
7. Remove the bracket and speed sensor.
t 8. Remove the motor component.

MOTOR
COMPONENT
arnffv00000619
9. Remove the oil seal.

_ - - - O I L SAEL
03-16-5
TRANSFER [SRSSS]
10. Remove the clutch coil terminal from the
connector and pull out the wiring harness from
-
the sleeve.
b5r5za00000304
11. Remove the two oil plugs from the rear transfer
case.
b5r5za00000305
12. Remove the 14 bolts and the identification tag.

BRACKET
b5r5za00000429
13. Pry at the transfer case projection as shown in the

figure a flathead screwdriver, and remove the rear
transfer case from the center transfer case.
Caution
• When prying at the transfer case, be
careful not to damage the case.
03-16-6
TRANSFER [SRSSS]
-14 Remove the spacer.. .
15: Using a flathead screwdnver, remove the 011 seal.
b5r5za00000457
16. Remove the snap ring. SNAPRING~

17. Pull out the ball bearing from the rear transfer
case. BALL BEARING ~
b5r5za00000430
18. Pull out the needle bearing from the rear transfer
case.
b5r5za00000431
19. Remove the return spring.
b5r5za00000309
20. Remove the 3 nuts.

21. Remove the clutch coil from the rear transfer
case.
NUT
b5r5za0000031 0
03-16-7
TRANSFER [5R55S]
22. Remove the snubber from the rear transfer case.
-
23. Clean and remove the sealant of the rear transfer
case and center transfer case.
Caution
• Be careful not to damage the metal
surface.
b5r5za00000412
24. Remove the clutch housing from the output shaft.
b5r5za00000312
25. Slide the lockup component and the lockup shift

fork component as a single unit to remove the
lockup component from the output shaft.
26. Remove the lockup shift fork component from the
lockup component.
b5r5za00000448
27. Remove the two fork facings from the lockup shift
fork.
FROK FACING
b5r5za00000459
28. Remove the snap ring, lockup hub and return

spring from the lockup collar. ~SNAPRING
~LOCKUPHUB
§ - R E T U R N SPRING
~~
~ LOCKUP COLLAR
b5r5za00000449
03-16-8
TRANSFER [SRSSS]
-29. Remove the snap ring and spacer from the output
shaft.
b5r5za00000450
30. Remove the drive chain, driven sprocket and drive DRIVEN
sprocket from the output shaft at a time. DRIVE
SPROCKET -id!lI.~
31. Separate the drive chain and sprockets.
b5r5za00000406
32. Remove the magnet from the slot in the center

transfer case.
33. Remove the strainer from the center transfer
case. ~---o-
' -_ _- STRAINER
34. Remove the output shaft component and gerotor

pump component from the center transfer case.
35. Remove the gerotor pump component from the

output shaft.
36. Loosen the hose clamp and remove the pump
OUTPUT SHAFT
hose from the gerotor pump component.
b5r5za00000408
03-16-9
TRANSFER [5R55S]
37. Remove the hose clamp, pump hose and strainer.
GEROTOR PUMP
COMPONENT
,
b5r5za00000460
38. Remove the reduction hub, reduction shift fork

component, rail shaft and shift shaft component
from the center transfer case. RAIL SHAFT SHIFT SHAFT
REDUCTION SHAFT
o 0 FORK COMPONENT
\~
REDUCTION HUB
b5r5za00000320 e
39. Remove the two shift fork facings from the
reduction shift fork component.
b5r5za00000432
40. Disassemble the cam, spring, spacer, and shift

shaft.
CAM
~~c£
SPRING
~ SPACER
SHlmHAB
'~
b5r5za0000045B
03-16-10
TRANSFER [SRSSS]
-41 Secure the flange using the SST.
42: Remove the nut and washer.
LOWER OUTPUT SHAFT
arnffv00000555
43. Remove the deflector from the flange.

44. Pull out the front output flange component.
45. Remove the lower output shaft.
@----DEFLECTOR
't----FLANGE
t 46.
arnffv00000616
Remove the oil seal from the lower output shaft.

47. Remove the deflector from the flange only when
replacement is necessary.
OIL SEAL OUTPUT SHAFT
@-~]~
b5r5za00000467
48. Remove the breather pipe.
BREATHER PIPE
b5r5za00000421
03-16-11
TRANSFER [SRSSS]
49. Remove the front transfer case six bolts.
50. Remove the front transfer case by separating the
-
adapter sealer bond using a flathead screwdriver.
Caution
• When prying at the transfer case, be
careful not to damage the case.
arnffv00000620
51. Remove the input shaft component and planetary

gear component from the front transfer case.
Note
• Expand the snap ring using the SST, and
separate the planetary gear component and
the input shaft component from the front
transfer case.
52. Remove the snap ring and oil seal from the front
transfer case.
b5r5za00000409
53. Remove the snap ring A.

SNAP RING A
54. Pull out the input shaft component and sun gear
from the planetary gear component.
55. Remove the snap ring B.
SNAP RING B PLANETARY GEAR COMPONENT

b5r5za00000324
56. Remove the ball bearing, thrust washer, thrust

plate and from the input shaft using the press.
arnffv00000603
57. Remove the needle bearing and bushing from the

input shaft component. BUSHING
NEEDLE BEARING
arnffv0000 0621
03-16-12
TRANSFER [5R55S]
-
58. Using a flathead sc.rewdriver, remove the oil seal.
59 Remove the snap ring. BEARING
60: Remove the ball bearing.
)
OIL SEAL
DOWEL PIN
b5r5za00000416
61. Remove the dowel pins from the center transfer

case.
Note
• Do not remove the ring gear from the center
transfer case.
b5r5za00000326
03-16-13
TRANSFER [SRSSS]
TRANSFER CASE ASSEMBLY[5R55S]
id0316C1S012OQ
Exploded View
Center transter_cas_e
4 Snap ring
03-16-14
TRANSFER [SRSSS]
48 Snap ring
49 Drive sprocket
50 Drive chain
51 Driven sprocket
52 Snap ring
53 Spacer
54 Lower output shaft
55 Front output flange component
56 Front output flange
57 Deflector
58 Oil seal
59 Washer
60 Locknut
61 Rear transfer case component
62 Rear transfer case
63 Needle bearing
64 Sleeve
65 Seal
66 Snubber
67 Bolt
68 Clutch coil
69 Nut
70 Clutch housing
71 Breather pipe
72 Speed sensor component
73 Bracket
74 Bolt
75 Spacer
76 Rear companion flange component
77 Rear companion flange
78 Oil plug
79 Motor component
80 Bracket
81 Terminal connector
82 Clip
83 Bracket
84 Clip
85 Bolt
86 Bolt
03-16-15
TRANSFER [SRSSS]
Assembly Procedure .
-
1. Insert two new dowel pins.
BEARIMG
OIL SEAL
b5r5za00000410
2 . Pre ss the ball bearing

T into the center transfer
case using the SS .
3. Install the snap ring.
arnffv00000596 t
4 Install the new oil seal, by pressing it into the
. center transfer case using the SST.
b5r5za00000462
5. Press the new nee die bearing into the input shaft
:rr(OjJ
using the SST.
NEEDLE BEARING
03-16-16
TRANSFER [5R55S]
-
6. Press the new bushing into the input shaft using
the SST.
7. Assemble the sun gear and thrust plate to the
SN6l~~!~EJ]~:~
input shaft.
It_U---~/-j I
GROOVE
SUN GEAR
THRUST WASHER
~:~e'r ·
PLANETARY GEAR
COMPONENT
arnffv00000625
8. Assemble the thrust washer and ball bearing to

the input shaft using the SST.
9. Install the snap ring B. I .1:
b5r5za00000437
10. Assemble the planetary gear component to the

planet carrier as shown in the figure.
Note
• Verify that the retaining ring is assembled to
the upper groove of the planetary gear
component on the workbench.
11. Install the snap ring A to the planetary gear

component.
b5r5za00000329
12. Press the new oil seal into the front transfer case
using the SST.
b5r5za00000463
03-16-17
TRANSFER [5R55S]
13. Install the snap ring by making sure that the snap
ring is correctly installed into the groove.
-
b5r5za00000331
14. Place the input shaft component onto the front

transfer case, and assemble the planetary gear
component to the groove while expanding the
ends of the snap ring using the SST.
b5r5za00000464
15. Apply sealant to the front transfer case as shown

in the figure.
b5r5za00000333
16. Install the front transfer case on the center

transfer case.
17. Install the six bolts and clip.
Tightening torque
34-41 N·m {3.5-4.1 kgf·m, 26-30 ft.lbf}
arnflv00000620
18. Install the breather pipe on the center transfer

case.
Tightening torque
4-7 N·m {41-71 kgf·cm,36-61 in·lbf}
BREATHER PIPE
b5r5za00000422
03-16-18
TRANSFER [SRSSS]
-19. Press in the new deflector to the flange using the
SST.
I •
arnffv00000597
20. Assemble the lower output shaft to the center

transfer case.
21. Assemble the front output flange component, oil
seal, washer, and nut.
22. Secure the flange using the SST.
23. Tighten the nut.
Tightening torque
305-332 N·m {31.2-33.8 kgf.m, 225-244
ft.lbf}
LOWER OUTPUT SHAFT
b5r5za00000466
I 24. Install the two-fork facing on the reduction shift

fork component.
b5r5za00000438
25. Install the reduction hub to the shift fork.

26. Install the reduction hub and shift fork component
to the planetary gear component.
b5r5za00000336
03-16-19
TRANSFER [5R55S]
27. Insert the spacer torsion spring and cam into the
-
shift shaft. C
B
b5r5za000004
28. Press them in until area A of the cam contacts

area B of the torsion spring, and area C of the B
torsion spring contacts area D of the shift shaft.
b5r5za000004·
29. Rotate the cam to the position indicated in the

figure, and press it to the shift shaft side until it D B
contacts the torsion spring.
b5r5za000004,
30. Install the cam component in the case as shown

in the picture. CAM COMPONENT
31. Verify that the reduction fork roller is seated in the
cam groove as shown in the figure.
32. Assemble the rail shift to the reduction fork bore.
0;:;:: I
b5r5za0000 041
03-16-20
TRANSFER [5R55S]
... -
33 Using a hose clamp, tighten the pump hose at the
. end where it is coupled with the strainer.
GEROTOR PUMP
COMPONENT
b5r5za00000452
39
34. Align the gerotor pump rotor slot and the pump
body slot so that they are in a single line.
arnffv00000598
40
35. Slide the gerotor pump component on the output
shaft over pump pin.
OUTPUT SHAFT
11 b5r5za00000419
36. Assemble the output shaft from the center

transfer case.
3? Assemble the output shaft spline to the reduction
hub.
38. Engage the output shaft end with the input shaft
bearing.
39. Couple the strainer with the case and insert the
magnet into the transfer case slot.
40. Assemble the drive sprocket to the output shaft.
41. Assemble the lower output shaft to the driven ~---o-
sprocket.
17
\--_ _- STRAINER
03-16-21
TRANSFER [SRSSS]
42. Install the drive chain onto the sprockets.
-
DRIVE DRIVEN
43. While keeping the tension of the drive chain,
assemble the transfer case and drive chain SPROCKET ~1"'n'"'1!"m
component in parallel.
44. While rotating the driven sprocket, engage it with
the front output shaft spline.
b5r5za000OO4Q
45. Assemble the spacer to the front output shaft.

46. Assemble the snap ring into the groove.
b5r5za0000045
47. Install the lockup hub and return spring to the lock
up collar and insert the snap ring. ~SNAPRING
~LOCKUPHUB
§-- RETURN SPRING
~I~
~ LOCKUP COLLAR
b5r5za0000044
48. Install the two new facings to the fork.
FROK FACING
b5r5za0000041
49. Assemble the lockup component to the lockup

fork, and assemble them to the drive shaft and the LOCKUP SHIFT
rail shaft. FORK COMPONENT
b5r5za000 0044 ;
03-16-22
TRANSFER [SRSSS]
-
50. Install the clutch housing on the output shaft.
b5r5za00000312
51. Position the end of the new needle bearing with

the identification mark facing upwards and press
it into the cover using the SST.
b5r5za00000442
52. Press the ball bearing into the rear transfer case
using the SST and install the snap ring.
b5r5za00000443
53. Install the coil inside the rear transfer case.

54. Install the three nuts.
Tightening torque
8-11 N·m {82-112 kgf·cm, 71-97 in.lbf}
NUT
b5r5za00000310
55. Install the snubber.
Tightening torque
8-11 N·m {82-112 kgf·cm, 71-97 in.lbf}
56. Install the return spring over rail shaft in the rear
, transfer case.
o
b5r5za00000412
03-16-23
Md,!
,],1'1"'"
TRANSFER [5R55S]
57. Apply a 1.6 mm {O.063 in} bead of sealant to the
-
transfer case mounting surface, and assemble the
cover and the transfer case.
Caution
• Do not use excessive force.
Note
• For installation of cover, align the cover with
transfer case.
58. Install the rear transfer case onto the center

transfer case as follows.
(1) Align the cover holes with the transfer case
dowel pins.
(2) Align the cover bearings with output shafts.
(3) Align the shift shaft with cover boss.
(4) Align the cover blind hole with rail shaft and b5r5za00000350
make sure that return spring is not cocked.
59. Install the 14 bolts identification tag and bracket.
BRACKET
b5r5za00000429
60. Install the new oil seal. _ _--OIL SAEL
61. Align the motor component with the shift shaft

and assemble it to the rear transfer case. MOTOR
62. Rotate the motor in clockwise direction to check COMPONENT
correct engagement.
arnffv00000615
03-16-24
TRANSFER [SRSSS]
-63. Install the speed sensor in the rear transfer case.
64. Install the bracket and bolts to the motor
component.
Tightening torque
8-11 N·m {82-112 kgf·cm, 71-97 in·lbf}
65. Pass the clutch coil wiring harness through the

sensor harness sleeve, and connect the coil
terminal to the connector.
66. Install the motor connector and sensor connector
to the motor bracket.
< b5r5za00000352
67. Bundle the wiring harness between the

speedometer component and terminal connector
using a wiring harness protector and tie wraps.
68. Install the oil plug to the rear transfer case.
Tightening torque
19-30 N·m {2.0-3.0 kgf·m, 15-22 ft.lbf}
03-16-25
TRANSFER [SRSSS]
69. Install the spacer over output shaft spline.
-
SP~ER~ o
"""-"...,.....'-
b5r5za00000454
70. Press the new oil seal into the rear transfer case
component using the SST.
I •
b5r5za00000445
71. Press in the new deflector to the flange using the

SST.
arnffv00000597
72. Install the rear companion flange component, oil

seal, washer and nut.
NUT~
73. Holding the rear companion flange using the SST,
tighten the nut. WASHER'@)
Tightening torque OILSEAL"@

305-332 N·m {31.2-33.8 kgf.cm, 225-244
in.lbf}
b5r5za00000355
TRANSFER CASE INSPECTION[5R55S]

id0316c1501300
Note
• Always replace the hose coupling, O-ring and oil seal with new parts.
1. Visually check all the parts for damage.

2. Referring to normal gear tooth face, specifically inspect the uneven wear and chips of gear tooth, replace if
necessary.
03-16-26
TECHNICAL DATA
-
03-50 TECHNICAL DATA
TeCHNICAL DATA ................. 03-50-1
TeCHNICAL DATA
DCF035000000W01
Item Specification
Maindrive gear bearing end play 0{}'-15 mm {0.OM059 in}
Mainshaft center bearing end play 0{}'-15 mm {0.OM059 in}
Maindrive gear bearing retaining ring

Thickness (mm {in})
2.60 {0.102}
2.67 {0.1 05}
2.74 {0.108}
Countershaft adjustment shim selective chart

Dimension A (mm {in}) Shim thickness (mm {in})
25.025.1
0.5 {0.020}
{0.985M88}
25.125.2
0.4 {0.016}
{0.989M92}
25.225.3
0.3 {0.012}
{0.993M96}
25.325.4
0.2 {0.008}
{0.997WOO}
25.425.5
0.1 {0.004}
{1.000W03}
I I 25.525.6
{1.004W07}
Mainshaft center bearing retaining ring

Thickness (mm {in})
3.1 {0.122}
3.2 {0.126}
3.3 {0.130}
,,
03-50-1
SERVICE TOOLS
-03-60 SERVICE TOOLS
SERVICE TOOLS .................. 03-60-1
I t-
SERVICE TOOLS
49 H017 101 490727415 490839425C
#
Hook Bearing Installer Bearing puller
set
49 E032 303 49 S120 710 49 F401 336B
cY
Bearing Coupling flange Attachment
Remover holder
~
49 H027 002 49 F026103 49 G028 203
Bearing Wheel Hub Support

remover Puller ~
~
t t 49 H001 628 49 F401 331 49 U025 001
Guide Pin Body Installer

Protector
49 F027 009 49 T019 005 49 G033107A
e
Attachment 68 Support Block Installer Dust
And 77 Cover
49 M005 797
Installer oil seal
03-60-1
SERVICE TOOLS [SRSSS]
-.......
, SERVICE TOOLS[5R55S]
id0360e1 SOo 1G;
307-611 307-605 307-607
<:
Repair fixture Snap ring pliers- Drift NRB input
adapter shaft
c::r (
307-606 307-608 307-609
(p q c====W
Drift ball Drift NRB fitting
0
Drift bush input
C
shaft bearing input cover
shaft
307-610 307-612 307-614
Drift ball
bearing
c@ Seal driver
c(( .~
Flange holder
front
(§)
307-613 307-615
c=CD
Flange holder Dust deflector
~
rear press tool
03-60....2
TRANSMISSIONITRANSAXLE 05
SECTION
,"MANUAL TRANSMISSION TECHNICAL DATA

[R1SM-D] ................ OS-11 A [S1SM-D, S1SMX-D] ........ OS-S08
MANUAL TRANSMISSION SERVICE TOOLS
[S1SM-D, S1SMX-D] ....... OS-118 [R1SM-D] ................ OS-60A
TECHNICAL DATA SERVICE TOOLS
[R1SM-D] ................ OS-SOA [S1SM-D, S1SMX-D] ........ OS-608
05-11-1
-05-118 MANUAL TRANSMISSION [S1SM-D, S1SMX-D]
PRECAUTION [S15M-D, S15MX-D] •... 05-11B-1 MANUAL TRANSMISSION PARTS
.TOP COVER COMPONENT AND INSPECTION [S15M-D, S15MX-D] ..•. 05-11 B-21
, EXTENSION HOUSING DISASSEMBLY SHIFT COMPONENT ASSEMBLY
[S15M-D, S15MX-D] .•..•••........ 05-11B-2 [S15M-D, S15MX-D] .•••.......•...• 05-11 B-23
REVERSE GEAR COMPONENT AND 1ST/2ND GEAR COMPONENT, 3RD/4TH
3RD/4TH GEAR COMPONENT GEAR COMPONENT AND
DISASSEMBLY ·COUNTERSHAFT ASSEMBLY
[S15M-D, S15MX-D] ..•.••.•..•.... 05-11B-9 [S15M-D, S15MX-D] .•••.......••... 05-11 B-26
MAINS HAFT COMPONENT, MAINS HAFT COMPONENT,
COUNTERSHAFT COMPONENT AND COUNTERSHAFT COMPONENT AND
TRANSMISSION CASE DISASSEMBLY TRANSMISSION CASE ASSEMBLY
[S15M-D, S15MX-D] .••.••••...•... 05-11B-13 [S15M-D, S15MX-D] ..•.•••....•.•.. 05-11 B-31
1ST/2ND GEAR COMPONENT, 3RD/4TH REVERSE GEAR COMPONENT AND
GEAR COMPONENT AND 3RD/4TH GEAR COMPONENT
COUNTERSHAFT DISASSEMBLY ASSEMBLY [S15M-D, S15MX-D] •...•• 05-11B-37
[S15M-D, S15MX-D] •••••.•.•...•.. 05-11B-16 TOP COVER COMPONENT AND
SHIFT COMPONENT DISASSEMBLY EXTENSION HOUSING ASSEMBLY
[S15M-D, S15MX-D] •.••....•...... 05-11 B-19 [S15M-D, S15MX-D] •...•••......•.. 05-11 B-44
PRECAUTION [S15M-D, S15MX-D]

DCF051100000W04
1. Clean the transmission exterior thoroughly using a steam cleaner or cleaning solvents before disassembly.
Warning
• Using compressed air can cause dirt and other particles to fly out, causing injury to the eyes.
Wear protective eye wear whenever using compressed air.
e Caution
• Cleaning sealed bearings using cleaning fluids or a steam cleaner can wash the grease out of the
bearing.
2. Clean the removed parts using cleaning solvent, and dry them using compressed air.
3. Clean out all holes and passages using compressed air, and check that there are no obstructions.
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 min after applying sealant. Allow all sealant to cure at least 30 min after
assembling before filling the transmission with transmission oil.
Warning
• Although the stand has a self-locking brake system, there is a possibility that the brake may not
hold when the transmission is held in a lopsided position on the stand. This would cause the
transmission to turn suddenly, causing serious injury. Never keep the transmission tilted to one
side. Always hold the rotating handle firmly when turning the transmission.
05-118-1
TOP COVER COMPONENT AND EXTENSION HOUSING DISASSEMBLY [S15M-D, S15MX-D]
DCF051117011W06
Caution
• Remove the oil seal (extension housing and control rod) only if there is a malfunction.
1. Disassemble in the order indicated in the table.

4x2
~\
~
B
DBG511 BMB001
05-118-2
1 Release fork 20 Spring cap

2 Release collar 21 Select lock spindle spring
3 Dust boot 22 Select lock spindle
Top cover, shift component Oil seal (extension housing)
4 23 (See 05-11 B-5 Oil Seal (extension housing)
(See 05-11 B-5 Top Cover Disassembly Note.)
5 Oil passage Removal Note.)
6 Control lever Extension housing
24 (See 05-118-6 Extension Housing Disassembly
7 Dust boot Note.)
8 Gasket 25 Funnel
9 Wave washer 26 Control rod
10 Change bush 27 Oil passage
11 Shift lever Oil seal (control rod)
12 Change seat 28 (See 05-11 B-6 Oil Seal (control rod) Disassembly
13 Control case Note.)
14 Control rod end Bush
29
(See 05-11 B-7 Bush Disassembly Note.)
15 Blind cover
Neutral switch Sealing cap
16 30
(See 05-11B-7 Sealing Cap Disassembly Note.)
17 Vehicle speed sensor
31 Retaining ring
18 Back-up light switch
32 Speed drive gear
19 Select spindle component
33 Steel ball
05-118-3
4x4
DBG511BMB063 ~
Release fork 5 Oil passage

2 Release collar 6 Control rod end
3 Dust boot 7 Dust boot
4 Top cover, shift component 8 Gasket
(See 05-118-5 Top Cover Disassembly Note.) 9 Wave washer
05-118-4
10 Change bush 23 Breather
('
11 Shift lever 24 Transfer
12 Transfer shift lever 25 Blind cover
13 Change seat Extension housing
14 Transfer neutral switch 26 (See 05-11 B-6 Extension Housing Disassembly
Note.)
15 Switch pin
27 Funnel
16 Spring
Oil seal (extension housing)
17 Steel ball 28 (See 05-11 B-5 Oil Seal (extension housing)
18 4x4 indicator switch Removal Note.}
19 Vehicle speed sensor Oil seal (control rod)
20 Neutral switch 29 (See 05-11 B-6 Oil Seal (control rod) Disassembly
Back-up light switch Note.}
21
22 Breather dust boot Bush
30
(See 05-11 B-7 Bush Disassembly Note.)
Oil Seal (extension housing) Removal Note

1. Remove the oil seal using a flathead screwdriver as shown in the figure.
4x2
DBG511 BMB003
4x4
DBG511 BMB077
Top Cover Disassembly Note

1. Pry the seal open at the projection on the case
using a flathead screwdriver or similar tool as
shown in the figure, and then remove the top
cover.
DBG511 BMB004
05-118-5
MANUAL TRANSMISSION [S15M-D, S15MX-D]
Extension Housing Disassembly Note
1. Remove the extension housing component.
Note
• Pry open the seal at the projection on the
case using a flathead screwdriver or similar
tool as shown in the figure, and then remove
the extension housing.
DBG511 BMB005
Oil Seal (control rod) Disassembly Note

1. Using a flathead screwdriver, remove the oil seal as shown in the figure.
4x2
DBG511 BMB006
4x4
DBG511 BMB068
05-118-6
Sealing Cap Disassembly Note
1. Remove the sealing cap using the SST.
Caution
• Remove the sealing cap only if there is
malfunction.
DBG511 BMB007
Bush Disassembly Note

4x2
1. Remove the bush using the SST.
DBG511 BMB075
2. Remove the bush using the suitable steel bar

through the sealing cap hole as shown in the 8
figure.
Distance A: Approx. 200 mm {7.87 in}
Oistance B: Approx.17.0-17.5 mm {0.670- A

0.688 in}
DBG511 BMB074
05-118-7
4x4
1. Remove the bush using the SST ..
Front side
DBG511 BMB073
Rear side
05-118-8
REVERSE GEAR COMPONENT AND 3RD/4TH GEAR COMPONENT DISASSEMBLY [S1SM-D, S1SMX-Dl
DCF05111 t030W11
t~ ____________________~______________~~ DBG511 BMB019
Locknut Countershaft rear bearing

(See 05-11 B-1 0 Mainshaft Rear Bearing locknut Thrust washer
and Countershaft Rear Bearing locknut
Disassembly Note.)
05-118-9
Locknut 22 Retaining ring

-
(See 05-11 B-1 0 Mainshaft Rear Bearing locknut 23 Washer
4 and Countershaft Rear Bearing locknut
Counter lever
Disassembly Note.) 24
(See 05-11 B-12 Counter Lever Disassembly Note.) C~
25 Retaining bolt
5 (See 05-11 B-11 Mainshaft Rear Bearing
Disassembly Note.) Counter lever shaft component
26
Reverse counter gear (See 05-11 B-12 Counter Lever Disassembly Note.)
6
27 Retaining bolt
7 Spacer
Retaining bolt 5th/reverse clutch hub and shift fork component
8
28 (See 05-118-12 5thlreverse Shift Fork
Reverse idler gear shaft c;:omponent Disassembly Note.)
9 (See 05-11 B-11 Reverse Idler Gear Shaft
Component Disassembly Note.) 29 5thlreverse shift fork
30 5th/reverse shift rod
10 Retaining ring
31 Detent ball
11 Thrust washer
12 Reverse idler gear 32 Detent spring
33 Clutch hub sleeve
13 Needle bearing
Thrust washer 34 Synchronizer key
14
15 Reverse idler gear shaft 35 Synchronizer key spring
36 5thlreverse clutch hub
Friction damper
16 (See 05-11 B-11 Reverse Idler Gear Friction 37 Synchronizer ring
Damper Disassembly Note.) 38 5th gear
17 Reverse gear 39 Needle bearing
18 Needle bearing 40 5rd gear bearing inner race
19 Thrust washer 41 Steel ball
20 Thrust washer 42 5th counter gear
21 Synchronizer ring
Mainshaft Rear Bearing locknut and Countershaft Rear Bearing locknut Disassembly Note
1. Slide the 3rd/4th and 1st/2nd clutch hub sleeves
to lock the transmission into 4th and 2nd gears.
2. Remove the countershaft rear bearing locknut by

rotating it clockwise.
DBG511 BMB027
05-118-10
3. Remove the mainshaft rear bearing locknut by
rotating it counterclockwise using the SST.
Mainshaft Rear Bearing Disassembly Note

1. Using the SSTs remove the mainshaft rear
bearing.
E5U511 BM5014
Reverse Idler Gear Shaft Component Disassembly Note

ita 1. Remove the reverse idler gear shaft retaining bolt ,.----------------------,
VI and then remove the reverse idler gear shaft
component from the transmission case.
E5U511 BM5015
Reverse Idler Gear Friction Damper Disassembly Note

1. Remove the friction damper using a flathead
screwdriver.
E5U511 BM5019
05-118-11
Counter Lever Disassembly Note
Caution
• To prevent the shaft position from
deviating when removing the counter
lever, remove the counters haft lever ~I~
component without loosening the
~~ D0
,
~
locknut unless it is necessary.
~I
, I
-
COUNTER LEVER
SHAFT
)~LOCKNUT
PLATE i
~
~
DBG511 BMB016
5th/reverse Shift Fork Disassembly Note

1. Remove the 5th/reverse shift rod retaining bolt.
2. Remove the 5th/reverse shift fork component and

5th/reverse clutch hub component at the same
time.
05-118-12
MAINSHAFT COMPONENT, COUNTERSHAFT COMPONENT AND TRANSMISSION CASE DISASSEMBLY
[S15M-D, S15MX-D]
DCF051117030W12
DBG511 BMB024
1 Bearing cover 6 Bearing shim

Front cover . Maindrive gear bearing race
2 7
(See 05-118-14 Front Cover Disassembly Note.) (See 05-11 B-14 Bearing Race Disassembly Note.)
3 Pivot pin Mainshaft bearing race
8 (See 05-11 B-14 Bearing Race Disassembly Note.)
4 Bearing shim
5 Oil baffle 9 Countershaft front bearing
05-118-13
10 Countershaft rear bearing Countershaft component

Mainshaft component 13 (See 05--118-14 Mainshaft Component and
It
11 (See 05-118-14 Mainshaft Component and Countershaft Component Disassembly Note.)
Countershaft Component Disassembly Note.) 14 Front oil seal
Maindrive gear 15 Transmission case
12 (See 05-118-14 Mainshaft Component and
Countershaft Component Disassembly Note.)
Front Cover Disassembly Note

1. Remove the front cover.
Caution
• Insert the front cover tightening bolts
into the bolt holes for the front cover
disassembly, tighten the two bolts
uniformly and, then remove the front
cover.
DBG511 BMB025
Bearing Race Disassembly Note

1. Grasping the mainshaft and countershaft, move
them forward and back to remove the bearing
races.
Mainshaft Component and Countershaft Component Disassembly Note

1. Tilt the mainshaft component as shown in the r------=:-------------------,
figure and remove it from the transmission case.
2. Remove the maindrive gear.
DBG511 BMB049
05-118-14
3. Tilt the countershaft component as shown in the
figure and remove it from the transmission case.
05-118-15
1ST/2ND GEAR COMPONENT, 3RD/4TH GEAR COMPONENT AND COUNTERSHAFT DISASSEMBLY [S15M-
-
D, S15MX-D]
DCF051117030W13
Caution
• Remove the countershaft center bearing race only if there is a malfunction.
DBG511 BMB026
1 Needle bearing Retaining ring

2 Scoop ring 6 (See 05-11 B-17 3rd/4th Clutch Hub Component
Disassembly Note.)
Maindrive gear shaft bearing
3 (See 05-11 B-18 Maindrive Gear Shaft Bearing 7 Spacer
Disassembly Note.) 8 Synchronizer ring
4 Maindrive gear shaft 9 Clutch hub sleeve
5 Needle bearing
05-118-16
3rd/4th clutch hub 25 Clutch hub sleeve

(See 05-11 B.,...17 3rd/4th Clutch Hub Component 1stl2nd clutch hub
Disassembly Note.) 26 (See 05-11 B-17 1stl2nd Clutch Hub Component
Disassembly Note.)
27 Synchronizer key spring
28 Synchronizer key
30 Double cone
31 Inner cone
32 2nd gear
33 Needle bearing
Countershaft center bearing race
34 (See 05-11 B-18 Countershaft Center Bearing Race
Disassembly Note.)
Countershaft front bearing race
35 (See 05-11 B-18 Countershaft Front Bearing Race
Disassembly Note.)
36 Countershaft
37 Mainshaft
3rd/4th Clutch Hub Component Disassembly Note

1. Remove the retaining ring using the two flathead
screwdrivers.
Caution
• Do not reuse the retaining ring.
FLATHEAD SCREW
DRIVERS
RETAINING RING
E5U5118M5010
2. Supporting the 3rd/4th clutch hub with your hand

as shown in the figure, tap the mainshaft with a
plastic hammer to remove the 3rd/4th clutch hub.
E5U5118M5022
1st/2nd Clutch Hub Component Disassembly Note

1. Using a press, remove the mainshaft center
bearing, 1st gear, 1st synchronizer ring
component, 1stl2nd clutch hub component, 2nd
synchronizer ring component and 2nd gear at the
same time.
Caution
• Be sure to support the mainshaft
component so that it does not fall.
05-118-17
-
Maindrive Gear Shaft Bearing Disassembly Note
1. Remove the maindrive gear shaft bearing using
the SST and press.
DBG511 BMB029
Countershaft Center Bearing Race Disassembly Note

1. Remove the countershaft center bearing race
using the SST and press.
Caution
• Be sure to support the countershaft so
that it does not fall.
Countershaft Front Bearing Race Disassembly Note

1. Remove the countershaft front bearing race using
the SST.
E5U511 BM5026
05-118-18
SHIFT COMPONENT DISASSEMBLY [S15M-D, S15MX-D]
DCF051117030W14
t 4X2
DBG511 BMB031
Retaining bolt 11 Interlock pin

2 Detent ball, spring 12 3rd/4th shift fork
3 Rubber plug . 13 Detent ball, spring seat, spring .~
4 5th/reverse shift rod end 14 1stl2nd shift rod end

5th/reverse shift rod 1stl2nd shift rod
5 15
(See 05-118-21 Shift Rod Disassembly Note.) (See 05--118-21 Shift Rod Disassembly Note.)
6 Interlock pin 16 1stl2nd shift fork
7· Interlock pin 17 Detent ball, spring seat, spring
8 Stopper block 18 8affle plate
9 3rd/4th shift rod end 19 8reather
3rd/4th shift rod
10 (See 05--118-21 Shift Rod Disassembly Note.)
05-118-19
-
DBG511 BMB036
Retaining bolt 16 3rd/4th shift rod

2 Detent ball, spring (See 05-11 B-21 Shift Rod Disassembly Note.)
3 Rubber plug 17 Interlock pin
4 5thlreverse shift rod end 18 3rd/4th shift fork
5 Retaining ring 19 Detent ball, spring seat, spring
6 Plain washer 20 1stl2nd shift rod end
7 Spring 21 Retaining ring
8 Push pin 22 Plain washer
9 Retaining ring 23 Spring
10 Detent ball, spring 24 Push pin
5th/reverse shift rod 25 1stl2nd shift rod
11 (See 05-11 B-21 Shift Rod Disassembly Note.)
(See 05-11 B-21 Shift Rod Disassembly Note.)
12 Interlock pin 26 1stl2nd shift fork
13 Interlock pin 27 Detent ball, spring seat, spring
14 Stopper block 28 Baffle plate
15 3rd/4th shift rod end 29 Breather
05-118-20
-
Shift Rod Disassembly Note
1. Remove the spring pins from each of the shift
rods using a pin punch.
2. Place the shift mechanism in the neutral position.
Caution
• When pulling out the shift rods, press the
top of each detent ball so that it doesn't
spring out.
DBG511 BMB033
3. Pull out the shift rods from the top cover.
DBG511 BMB034
MANUAL TRANSMISSION PARTS INSPECTION [S15M-D, S15MX-D]

DCF051100000W05
Clutch Hub Component
1. Measure the clearance between each shift fork
and clutch hub sleeve groove using a feeler
gauge.
• If not within the specification, replace the shift
fork and clutch hub sleeve as a set.
Standard clearance between shift fork and

clufch hub sleeve groove
0.05-0.40 mm {0.002-0.015 in}
Maximum clearance between shift fork and

clutch hub sleeve groove
BHJ0511M018
0.5 mm {0.020 in}
Synchronizer Ring
1. Measure the clearance between the synchronizer
ring and flank surface of the gear using a feeler
gauge around the entire circumference .
synchronizer ring.
Standard clearance between synchronizer

ring and flank surface of gear
1.5 mm {0.059 in}
Maximum clearance between synchronizer

ring and flank surface of gear
BHJ0511 M020
0.8 mm {0.031 in}
Note
• Set the synchronizer ring squarely in the gear.
05-118-21
-
Spring
1. Measure the free length of each spring.
spring.
Detent ball springs for 1st/2nd and 3rd/4th

shift rods
Standard length: 22.5 mm {0.886 in}
Detent ball spring for 5th/reverse shift rod

1st/2nd select lock spindle spring [4x2]

BHE0511 M023
Push pin spring for 1st/2nd shift rod end [4x4]

Standard length: 32.8 mm {1.29 in).
Push pin spring for 5th/reverse shift rod end [4x4]

Detent ball spring for 5th/reverse shift rod end [4x4]

Mainshaft
1. Measure the mainshaft runout using a dial gauge.
replace the mainshaft.
Mainshaft maximum runout

0.03 mm {0.0012 in}
1
DBG511 BMB035
Shift Rod End, Control Lever

1. Measure the clearance between the shift rod end
and control lever using a feeler gauge.
• If not within the specification, replace the shift
rod end or control lever as a set.
Standard clearance between shift rod end and

control lever
0.5 mm {0.020 in} or less
DBG511 BMB022
05-118-22
, ,
tri
SHIFT COMPONENT ASSEMBLY [S15M-D, S15MX-D]
DCF051117030W15
4x2
1 7.8-11.8 N·m {80-120 kgf·cm, 70-104 in·lbf}
DBG511 BMB037
1 Breather 10 3rd/4th shift fork

2 Baffle plate 11 Interlock pin
3 Detent ball, spring seat, spring 12 Interlock pin "
1sV2nd shift rod 13 3rd/4th shift rod end
4
(See 05-11 B-25 Shift Rod Assembly Note.) 5th/reverse shift rod
14
5 1sV2nd shift fork (See 05-11 B-25 Shift Rod Assembly Note.)
6 1sV2nd shift rod end 15 Stopper block
7 Interlock pin 16 5th/reverse shift rod end
8 Detent ball, spring seat, spring 17 Rubber plug
3rd/4th shift rod 18 Detent ball, spring
9
(See 05-118--25 Shift Rod Assembly Note.) 19 Retaining bolt
05-118-23
4x4
-
1 7.8-11.8 N·m {80-120 kgf·cm, 70-104 in·lbf}

DBG511 BMB038
Breather 16 Interlock pin

2 Baffle plate 17 Interlock pin
3 Detent ball, spring seat, spring 5th/reverse shift rod
18
1st/2nd shift rod . (See 05-11 B-25 Shift Rod Assembly Note.)
4
(See 05-11 B-25 Shift Rod Assembly Note.) 19 Stopper block
5 1st/2nd shift fork 20 Detent ball, spring
6 Push pin 21 Retaining ring
7 Spring Push pin
22
8 Plain washer (See 05-11 B-25 Push Pin Assembly Note.)
9 Retaining ring 23 Spring
10 1st/2nd shift rod end 24 Plain washer
11 Interlock pin 25 Retaining ring
12 Detent ball, spring seat, spring 26 5th/reverse shift rod end
3rd/4th shift rod 27 Rubber plug
13 (See 05-11 B-25 Shift Rod Assembly Note.) 28 Detent ball, spring
14' 3rd/4th shift fork 29 Retaining bolt
15 3rd/4th shift rod end
05-118-24
Shift Rod Assembly Note
1. Install each shift rod.
Caution
• Do not forget to insert the interlock pins.
Note
• Insert the shift rod while pressing the detent
ball with a flathead screwdriver as shown in
the figure.
DBG511 BMB039
Push Pin Assembly Note

1. Install the push pin.
Note
• Insert the push pin while pressing the detent
ball with a flathead screwdriver as shown in
the figure.
DBG511 BMB040
05-118-25
1ST/2ND GEAR COMPONENT, 3RD/4TH GEAR COMPONENT AND COUNTERSHAFT ASSEMBLY [S15M-D,
S15MX-D]
DCF051117040VV07
r1_,_A_S_S_e~m~b=le=in~th_e_O_rd_e_r_in_d_iC_a_te_d__
in_th_e_t_a_b_le_,__________________________________________"
-.-.-
I APPLY SPECIFIED OIL TO INDIVIDUAL PARTS
DBG511 BMB041
1 Mainshaft 1st/2nd clutch hub

2 Needle bearing 7 (See 05-118-27 1st/2nd Clutch Hub Component
Assembly Note,)
3 2nd gear
8 Synchronizer key
4 Inner cone
9 Synchronizer key spring
5 Double cone
10 Clutch hub sleeve
6 Synchronizer ring
05-118-26
Synchronizer ring Clutch hub sleeve

Double cone 26 (See 05-11 B-28 3rd/4th Clutch Hub Component
Assembly Note.)
Inner cone
1st gear
28 Spacer
Needle bearing
Retaining ring
1st gear bearing inner race 29 (See 05-11 B-28 3rd/4th Clutch Hub Component
Mainshaft center bearing Assembly Note.)
(See 05-11 B-27 1st/2nd Clutch Hub Component 30 Needle bearing
Assembly Note.)
31 Maindrive gear
18 Needle bearing
Maindrive gear shaft bearing
19 3rd gear 32 (See 05-11 B-29 Maindrive Gear Shaft Bearing
20 Inner cone Assembly Note.)
21 Double cone 33 Scoop ring
22 Synchronizer ring 34 Needle bearing
Clutch hub 35 Countershaft
23 (See 05-11 B-28 3rd/4th Clutch Hub Component Countershaft center bearing race
Assembly Note.) 36 (See 05-11 B-29 Counters haft Center Bearing Race
Synchronizer key Assembly Note.)
24 (See 05-11 B-28 3rd/4th Clutch Hub Component Countershaft front bearing race
Assembly Note.) 37 (See 05-11 B-30 Counters haft Front Bearing Race
Synchronizer key spring Assembly Note.)
25 (See 05-11 B-28 3rd/4th Clutch Hub Component
Assembly Note.)
1stl2nd Clutch Hub Component Assembly Note

Caution
• Be sure to assemble the clutch hub
components and synchronizer ring
components while aligning the
F:A=Jg
synchronizer ring grooves with the
_1= u
synchronizer" keys.
,. The standard synchronizer key
dimensions are as follows:
mm {in}
~
1st/2nd 117.0 ~.669} 1 5.9 ~.23} 5.0 ~.20} 1
A6E5110M131
• Be sure to align the synchronizer ring

projections with the inner cone notches.
• Be sure to assemble the gears and the
synchronizer ring components while
aligning the double cone projections with
the gear holes as shown in the figure.
DBG511 BMB042
05-118-27
• Align the clutch hub sleeve alignment
mark with the clutch hub synchronizer _o::::=-....,----ALIGNMENT MARK
key installation position and assemble. ~~~~~,,-SYNCHRONIZER KEY
Caution
• When using a press, be careful not to
damage the parts.
E5U511 BM5058
1. Using a SSTs and press, assemble the needle

bearing, 2nd gear, synchronizer ring component
(2nd), 1sV2nd clutch hub component,
synchronizer ring component (1 st), 1st gear,
needle bearing, needle bearing race and
mainshaft center bearing to the mainshaft at the
same time.
" I II
DBG511 BMB043
3rd/4th Clutch Hub Component Assembly Note

1. Assemble the 3rd/4th clutch hub component.
Caution
• The standard synchronizer key
mm {in}
A B C
3rd/4th 17.0 {0.669} 5.9 {0.23} , 5.0 {0.20}
A6E5110M131
• Be sure to align the synchronizer ring

projections with the inner cone notches.
• Be sure to assemble the gears and the
synchronizer ring components while
aligning the double cone projections with
the gear holes as shown in the figure.
DBG511 BMB042
05-118-28
_O=:",-<:~_-ALIGNMENTMARK
mark with the clutch hub synchronizer
key installation position and assemble. ~~~~~~SYNCHRONIZER KEY
2. Install the 3rd/4th clutch hub component to the

mainshaft.
3. Install the spacer.
5. Measure the clearance between retaining ring

and spacer.
chOOSing the proper retaining ring.
3rd/4th clutch hub end play

0-0.05 mm {0.0-0.0019 in}
3rd/4th clutch hub retaining ring

Thickness (mm {in})
1.50 {0.0591}
1.55 {0.0610} DBG511 BMB044
1.60 {0.0630}
1.65 {0.0650}
1.70 {0.0669}
1.75 {0.0689}
1.80 {0.0709}
1.85 {0.0728}
1.90 {0.0748}
1.95 {0.0768}
Maindrive Gear Shaft Bearing Assembly Note

1. Assemble the maindrive gear shaft bearing using
the SSTs.
DBG511 BMB062
Countershaft Center Bearing Race Assembly Note

1. Assemble tile countershaft center bearing race
using the SSTs.
DBG511 BMB046
05-118-29
,
Countershaft Front Bearing Race Assembly Note
-
1. Assemble the countershaft front bearing race
using the SSTs.
II •
DBG511 BMB047
05-118-30
-
MAINSHAFT COMPONENT, COUNTERSHAFT COMPONENT AND TRANSMISSION CASE ASSEMBLY
[S1SM-D, S1SMX-D]
DCF051117040W08
31-46
{3.2-4.6, 23-33}
17.7-26.4
{1.81-2.69,13.1-19.4}
N·m {kgf.m, ft.lbf}
DBG511 BMB048
1 Transmission case Mainshaft component

Counters haft component (See 05-118-32 Maindrive Gear Component,
3 Mainshaft Component and Countershaft
(See 05-118-32 Maindrive Gear Component,
2 Component Assembly Note.)
Mainshaft Component and Countershaft
Component Assembly Note.)
05-118-31
5
Maindrive gear
(See 05-11 B-32 Maindrive Gear Component,
Mainshaft Component and Countershaft
Countershaft front bearing
10
11
12
13
Front oil seal
(See 05-11 B-32 Front Oil Seal Assembly Note.)
Bearing shim
Bearing shim
Oil baffle
,;
6 Countershaft rear bearing
14 Pivot pin
7 Maindrive gear bearing race
Front cover
8 Mainshaft bearing race (See 05-11 B-32 Maindrive Gear Component,
15
9 Bearing cover Mainshaft Component and Countershaft
Front Oil Seal Assembly Note

2. Install the oil seal to the front cover using the
SST.
~. I:
Maindrive Gear Component, Mainshaft Component and Countershaft Component Assembly Note
1. Install the countershaft component.
2. Install the maindrive gear.
E5U511 BM5073
3. Install the mainshaft component.
DBG511 BMB049
05-118-32
4. Assemble the Mainshaft component and
Maindrive gear.
5. Install the countershaft front and rear bearing.
E5U511 BM5046
6. Install the maindrive gear bearing race and

mainshaft center bearing race.
E5U511 BM5047
7. Install the bearing cover with the arrow painting to

the top of the case.
Tightening torque:
17.7-26.4 N·m {1.81-2.69 kgf·m, 13.1-19.4
ft.lbf}
E5U511 BM5048
05-118-33
8. Select the mainshaft component and countershaft component bearing shims according to the following
procedure.
(1) Set the clutch housing side upward and level the transmission case.
Caution
• Securely assemble the mainshaft, maindrive gear component, and countershaft component so
that there is no looseness or play.
(2) Using a depth gauge, measure the maindrive

gear bearing outer race height A.
DBG511 BMB054
(3) Using a depth gage, measure the main drive

DEPTH GAUGE
gear bearing retainer depth B.
(4) Calculate and select the correct maindrive
gear bearing shim thickness.
Formula: C = B - A
C: Dimension between the maindrive gear

bearing and bore in the front cover
B: Depth of the maindrive gear bearing bore
in the front cover
A: Maindrive gear bearing height
DBG511 BMB055
• Refer to the maindrive gear bearing shim

selective chart.
Maindrive gear bearing shim selective chart

Dimension C (mm {in}) Shim thickness (mm {in})
1.45-1.55
1.4 {0.055}
{0.0571-0.0610}
1.55-1.65
1.5 {0.059}
{0.0611-0.0649}
1.65-1.75
1.6 {0.063}
{0.0650-0.0688}
1.75-1.85
1.7 {0.067}
{0.0689-0.0728}
1.85-1.95
1.8 {0.071}
{0.0729-0.0767}
1.95-2.05
1.9 {0.075}
{0.0768-0.0807}
2.05-2.15
2.0 {0.079}
{0.0808-0.0846}
2.15-2.25
2.1 {0.083}
{0.0847-0.0885}
2.25-2.35
2.2 {0.087}
{0.0886-0.0925}
2.35-2.45
2.3 {0.090}
{0.0926-0.0964}
2.45-2.55
2.4 {0.094}
{0.0965-0.1003}
2.55-2.65
2.5 {0.098}
{0.1 004-0.1 043}
05-118-34
MANUAL TRANSMISSION [S15M-O, S15MX-O]

2.65-2.75
2.6 {0.102}
{0.1 044-0.1 082}
2.75-2.85
2.7 {0.106}
{0.1083-0.1122}
2.85-2.95
2.8 {0.110}
{0.1123-0.1161}
2.95-3.05
2.9 {0.114}
{0.1162-0.1200}
3.05-3.15
3.0 {0.118}
{0.1201-0.1240}
Maindrive gear shaft total end play

0.05-0.15 mm {0.002-0.0059 in}
(5) Using a depth gauge, measure the

countershaft front bearing depth D.
Note
• The countershaft bearing is located below
the contact surface of the case and front
cover.
DBG511 BMB056
(6) Using a depth gauge, measure the

countershaft front bearing retainer depth 'E.
(7) Calculate and select the correct countershaft
front bearing shim thickness.
Formula: F = E + D
F: Dimension between the countershaft
front bearing and bore in the front cover
E: Depth of the countershaft front bearing
bore in the front cover
D: Countershaft front bearing depth
DBG511 BMB057
• Refer to the countershaft front bearing
shim selective chart.
Countershaft front bearing shim selective chart

Dimension F (mm {in}) Shim thickness (mm {in})
3.15-3.25
3.0 {0.118}
{0.124Q-0.1279}
3.25-3.35
3.1 {0.122}
{0.128Q-0.1318}
3.35-3.45
3.2 {0.126}
{0.1319-0.1358}
3.45-3.55
3.3 {0.130}
{0.1359-0.1397}
3.55-3.65
3.4 {0.134}
{0.1398-0.1437}
3.65-3.75
3.5 {0.138}
{0.1438-0.1476}
3.75-3.85
3.6 {0.142}
{0.1477-0.1515}
3.85-3.95
3.7 {0.147}
{0.1516-0.1555}
Counters haft total end play

0.15-0.25 mm {0.006-0.0098 in}
05-118-35
....

9. Position the maindrive gear bearing shim, oil baffle, and the countershaft bearing shim onto the front cover.
Note
• If necessary, apply a light coat of petroleum jelly to the shims and oil baffle.

transmission case and front cover as shown in the
figure.
11. Install the pivot pin.
Tightening torque:
31-46 N·m {3.2-4.6 kgf.m, 23-33 ft·lbf}
DBG511 BMB053
12. Install the front cover to the transmission case.
Tightening torque:
19-25 N·m {2.0-2.5 kgf·m, 15-18 ft.lbf}
Note
• To prevent damage to the oil seal lip during
assembly, tape maindrive gear shaft splines.
DBG511 BMB052
05-118-36
REVERSE GEAR COMPONENT AND 3RD/4TH GEAR COMPONENT ASSEMBLY [S15M-D, S15MX-0l
DCFt'!51117040W09
211-269
{21.6-27.4,156-198}
SELECTIVE
IAPPLY SPECIFIED OIL TO INDIVIDUAL PARTS

127-196
{13.D-19.9,94-144} N·m {kgf.m, ft·lbf}
DBG511 BMB058
15th counter gear 5rd gear bearing inner race

Steel ball 3 (See 05-11 B-38 5th Gear Bearing Inner Race
Assembly Note.)
05-118-37
4 Needle bearing 27 Friction damper

55th gear 28 Reverse idler gear shaft
6 Synchronizer ring 29 Thrust washer
75th/reverse clutch hub 30 Needle bearing
8 Synchronizer key spring 31 Reverse idler gear
9 Synchronizer key 32 Thrust washer
10 Clutch hub sleeve 33 Retaining ring
11 Detent spring Reverse idler gear shaft component
12 Detent ball 34 (See 05-11 B-41 Reverse Idler Gear Component
Assembly Note.)
13 5th/reverse shift rod
35 Retaining bolt
14 5th/reverse shift fork
36 Spacer
5th/reverse clutch hub and shift fork component
(See 05-11 B-39 5th Counter Gear, 5th/Reverse 37 Reverse counter gear
15
Clutc~ Hub Component and 5th/Reverse Shift Fork Mainshaft rear bearing
Assembly Note.) (See 05-11 B-42 Mainshaft Rear Bearing and
38
16 Retaining bolt Counters haft Rear Bearing Locknut Assembly
Note.)
Counter lever shaft component
17 (See 05-11 B-41 Counter Lever Shaft Assembly Locknut
Note.) (See 05-11 8-42 Mainshaft Rear Bearing and
39
Countershaft Rear Bearing Locknut Assembly
18 Retaining bolt Note.)
19 Counter lever 40 Thrust washer
20 Washer Countershaft rear bearing
21 Retaining ring (See 05-11 B-42 Mainshaft Rear Bearing and
41
22 Thrust washer Counters haft Rear Bearing Locknut Assembly
23 Thrust washer Note.)
24 Spacer Locknut
(See 05-118-42 Mainshaft Rear Bearing and
25 Needle bearing 42
Countershaft Rear Bearing Locknut Assembly
Reverse gear Note.)
26
(See 05-11 B-40 Reverse Gear Assembly Note.)
5th Gear Bearing Inner Race Assembly Note

1. Install the steel ball to the countershaft.
2. Align the ball groove position of the 5rd gear
bearing inner race and assemble it to the
countershaft.
E5U511 BM5032
05-118-38
5th Counter Gear, 5th/Reverse Clutch Hub Component and 5th/Reverse Shift Fork Assembly Note
1. Assemble the 5th drive gear and 5th/reverse clutch hub component.
Caution
• Be sure to assemble the clutch hub components and synchronizer ring components while aligning
the synchronizer ring grooves with the synchronizer keys.
• The standard synchronizer key r---------------------,
mm {in}
A B c
5th/6th 18.0 {0.709} 5.45 {0.215} 6.0 {0.236}
A6E5110M131

mark with the clutch hub synchronizer _o:=:::-..::----ALIGNMENTMARK
key installation position and assemble. ~~~~~,,-SYNCHRONIZER KEY
, 2. Assemble the 5th counter gear component, 5th/

reverse clutch hub component, and 5th/reverse
E5U511 BM5058
shift fork component as a single unit.
3. Install the 5th/reverse shift rod retaining bolt.
Tightening torque:
21.6-30.4 N·m {2.21-3.09 kgf·m, 16.0-22.4
ft.lbf}
4. Install the thrust washer.
05-118-39
-
5. Measure the clearance between thrust washer
and groove of the countershaft.
choosing the proper thrust washer.
5th/Reverse clutch hub end play 5TH/REVERSE

0-0.05 mm {0.0-0.0019 in} CLUTCH HUB
END PLAY
5th/Reverse clutch hub thrust washer
Thickness (mm {in})
3.00 {0.11B}
3.05 {0.120} DBG511 BMB060
3.10 {0.122}
3.15 {0.124}
3.20 {0.126}
3.25 {0.12B}
3.30 {0.130}
3.35 {0.132}
3.40 {0.134}
Reverse Gear Assembly Note

1. Measure the clearance A and B.
(1) Calculate and select the thrust washer
thickness.
Formula: C = A - B
B
C: Dimension between the 5th/Reverse
clutch hub and reverse gear
B: Reverse gear height
A: Dimension between the 5th/Reverse
REVERSE GEAR
clutch hub and thrust washer
DBG511 BMB061
• Refer to the reverse gear thrust washer
selective chart.
Reverse gear thrust washer

Dimension C (mm {in}) Thickness (mm {in})
7.70-7.BO
7.45 {0.293}
{0.304-0.307}
7.BO-7.90
7.55 {0.297}
{0.30B-0.311}
7.90-B.00
7.65 {0.301}
{0.312-0.314}
B.00-8.10
7.75 {0.305}
{0.315-0.31B}
Reverse gear end play

0.25-0.35 mm {0.002-0.0059 in}
2. Install the thrust washer.

3. Install the reverse gear.
05-118-40
Counter Lever Shaft Assembly Note
1. Install the counter lever shaft component.
Caution
• If the counter lever shaft has been
replaced or the locknut is loose,
assemble the counter lever shaft with the
chamfer side of the shaft pOinted straight
upward.
• Apply sealant to the threads of the
locknut.
• If there is an abnormality in the 3rd/4th
shift stroke after assembling, loosen the
E5U511 BM5072
locknut and readjust.
Locknut tightening torque:

37.3-51.9 N·m {3.81-5.29 kgf·m, 27.6-38.2 ft.lbf}
Reverse Idler Gear Component Assembly Note

1. Using the SSTs, install the friction damper to the
reverse idler gear.
ICTION DAMPER
DBG511 BMB078
• Verify the depth of the friction damper

installation position. 1.0-1.6 mm {0.040-0.062 in}
FRICTION DAMPER
2. Assemble the reverse idler gear component.

3. Measure the clearance between the retaining ring
and thrust washer.
Reverse idler gear end play

0.1-0.2 mm {0.0040-0.0078 in}
Reverse idler gear retaining ring

Thickness (mm {in})
1.5 {O.059}
• 1.6 {O.063}
)" 1.7 {O.067}
r---------------~~~~--------------~
1.8 {O.071}
1.9{O.075}
05-118-41
4. Install the reverse idler gear component to the
-
transmission case.
E5U511 BM5070
5. Install the reverse idler gear shaft retaining bolt.
Tightening torque
78.5-117 N·m {8.01-11.9 kgf·m, 57.9-86.2
ft.lbf}
E5U511 BM5015
Mainshaft Rear Bearing and Countershaft Rear Bearing Locknut Assembly Note
1. Slide the 3rd/4th and 1sV2nd clutch hub sleeves r----------------------,
to lock the transmission into 4th and 2nd gears.
2. Insert the mainshaft rear bearing into the
mainshaft and install the locknut.
3. Attach the SST to the locknut and tighten the nut to the specified torque.
Caution
• Attach the SST with the locknut seated in
the bearing.
Tightening torque:
211-269 N·m {21.6-27.4 kgf.m, 156-198
ft·lbf}
DBG511 BMB028
05-118-42
4. Tighten the countershaft locknut in the
counterclockwise direction.
Tightening torque:
127-196 N·m {13.0-19.9 kgf·m, 94-144
ft.lbf}
5. Using the pin punch, stake the mainshaft rear

bearing locknut.
6. Using the pin punch, stake the countershaft rear

bearing locknut.
05-118-43
TOP COVER COMPONENT AND EXTENSION HOUSING ASSEMBLY [S15M-D, S15MX-D]
--..e
DCF051117011W07
4r-X_2_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _
15.7-22.5 ~
{1.60-2.29,11.6-16.5} I
19
7.S-11.0 N·m
~ {S0-112 kgf.cm,
1i' 70-97 in.lbf}
J~~~
~m
~
~
15.7-22.5
1/
{1.60-2.29, ,
7.9-9.S N.m 11.6-16.5}
{S1-99 kgf·cm,
70-86 ;".Ib"~
~\\~
~~~
7.S-11.0N·m
{S0-112 kgf·cm,
70-97 in.lbf}
~ _./'1 .............. __ ---...J
~ I \
f\..
~
~
7.8-11.0 N·m
{S0-112 kgf.cm,
70-97 in·lbf}
~
m
25-34
~
iii"
{2.55-3.46,
1S.5-25.0}
6.9-9.S N·m
{71-99 kgf·cm, 61-S6 in.lbf}
DBG511 BMB002
ISteel ball 3 IRetaining ring ]
05-118-44
Bush Top cover, shift component

4 19
(see 05-11 B-47 Bush Assembly Note.) (see 05-11 B-50 Top Cover Assembly Note.)
Oil seal (control rod) Blind cover
) 5 (see 05-11 B-48 Oil Seal (control rod) Assembly
20
(see 05-11 B-51 Blind Cover Assembly Note.)
Note.) 21 Control case
Sealing cap 22 Change seat
6
(see 05-11 B-49 Sealing Cap Assembly Note.)
23 Shift lever
7 Control rod
24 Change bush
8 Oil passage
25 Wave washer
9 Funnel
26 Gasket
Extension housing
(see 05-11 B-50 Extension Housing Assembly 27 Dust boot
10
Note.) 28 Neutral switch
11 Control rod end 29 Vehicle speed sensor
12 Select spindle component 30 Back-up light switch
13 Select lock spindle 31 Dust boot
14 Select lock spindle spring Release fork
32 (see 05-11 B-51 Release Collar, Release Fork
15 Spring cap
Assembly Note.)
Oil seal (extension housing)
16 (see 05-11 B-49 Oil Seal (Extension Housing) Release collar
Assembly Note.) 33 (see 05-11 B-51 Release Collar, Release Fork
Assembly Note.)
17 Control lever
18 Oil passage
05-118-45
4x4
-
15.7-22.5
{1.60-2.29,11.6-16.5}
.----1I
~K m l
f
1
~o
7.8-11.0N·m 3 •
{80-112kgf.cm, ~ ~
7_"'~
7.8-11.0 N·m
{80-112 kgf.cm,
70-97 in·fbf}
ti
'">\
7.9-9.8N·m
{81-99 kgf.cm,
~
70--116 Jil3m
~ ~ 25-34
{2.6-3.4, 19-25}
~~m
~ ~;;;:'~.4, 19-25}
N·m {kgf.m, tt·fbf}
DBG511 BMB064 f'

Bush Oil seal (extension housing)
1
(see 05-11 B-47 Bush Assembly Note.) 3 (see 05-11 B-49 Oil Seal (Extension Housing)
Oil seal (control rod) Assembly Note.)
2 (see 05-11B-48 Oil Seal (control rod) Assembly 4 Funnel
Note.)
05-118-46
Extension housing 19 Transfer shift lever

5 (see 05-11 B-:-50 Extension Housing Assembly 20 Shift lever
Note.)
21 Change bush
Blind cover
6 22 Wave washer
(see 05-118-51 Blind Cover Assembly Note.)
23 Gasket
7 Transfer
24 Dust boot
Breather
8 (see 05-118-51 Breather Assembly Note.) 25 Control rod end
9 Breather dust boot 26 Oil passage
10 Back-up light switch Top cover, shift component
27
(see 05-11 B-50 Top Cover Assembly Note.)
11 Neutral switch
28 Dust boot
12 Vehicle speed sensor
Release collar
13 4X4 indicator switch
29 (see 05-11 B-51 Release Collar, Release Fork
14 Steel ball Assembly Note.)
15 Spring Release fork
16 Switch pin 30 (see 05-11 B-51 Release Collar, Release Fork
17 Transfer neutral switch Assembly Note.)
18 Change seat
Bush Assembly Note

4x2
1. Install the bush using the SST.
Installation depth A: 1-2 mm {0.040-0.078

in}
DBG511 BMB069
2. Install the bush using the suitable steel bar

through the sealing cap hole as shown in the
figure.
Distance A: Approx. 200 mm {7.87 in}
Distance B: Approx.17.0-17.5 mm {0.S70-

0.S88 in}
Installation depth C: 1-2 mm {0.040-0.078

in}
DBG511 BMB070
OS-11B-4J:
-
4x4
1. Install the bush using the SST.
Front side
Installation depth A: 0-1 mm {0.0-0.039 in}
DBG511 BMB071
Rear side
Installation depth A: 1-2 mm {0.040-0.078

in}
DBG511 BMB072
Oil Seal (control rod) Assembly Note

4x2
2. Install the oil seal using the SSTs through the
sealing cap hole as shown in the figure.
Installation depth A: 109.5-110.5 mm

{4.312-4.350 in}
05-118-48
4x4
2. Install the oil seal using the SST.

0.118 in}
DBG511 BMB066
Sealing Cap Assembly Note

1. Install the sealing cap using the SSTs.
Caution
• Apply silicone sealant to the sealing cap.

0.078 in}
<I. : I I:
DBG511 BMB015
Oil Seal (Extension Housing) Assembly Note

2. Install the oil seal evenly and gradually using the SST and a hammer.
4x2
05-118-49
4x4

1.94 in}
DBG511 BMB06?
Extension Housing Assembly Note

extension housing and transmission case as
2. Install the extension housing to the transmission
case.
Tightening torque:
31.4-46.0 N·m {3.21-4.69 kgf·m, 23.2-33.9
ft.lbf}
DBG511 BMB008
Top Cover Assembly Note

transmission case and top cover as shown in the
figure.
2. Install the top cover component to the
transmission case.
Tightening torque:
15.7-22.5 N·m {1.60-2.29 kgf·m, 11.6-16.5
ft·lbf}
DBG511 BMB009
Control Case Assembly Note

control case and extension housing as shown in
the figure.
2. Install the control case to the extension housing.
Tightening torque:
15.7-22.5 N·m {1.60-2.29 kgf·m, 11.6-16.5
ft·lbf}
DBG511BMB010
05-118-50
Blind Cover Assembly Note
1. Apply sealant to the contact surfaces of the blind
cover and extension housing as shown in the
figure.
2. Install the blind cover to the extension housing.
Tightening torque:
7.9-9.8 N·m {81-99 kgf·cm, 70-86 in·lbf}
DBG511BMB011
Breather Assembly Note

1. Install the new breather using the SST.
DBG316BMB044
. Release Collar, Release Fork Assembly Note

, 1. Apply specified grease to the areas shown in the
figure.
2. Install the release collar and release fork.
-Ii'
11
DBG511 BMB023
05-118-51
05-13 AUTOMATIC TRANSMISSION [5R55S]
AUTOMATIC TRANSMISSION OVERDRIVE PLANETARY GEAR AND
DISASSEMBLY[5R5SS] ....•••..... OS-13-2 ONE-WAY CLUTCH COMPONENT
FLUID PUMP DISASSEMBLY DISASSEMBLY/ASSEMBLY
,. [SRSSS] ••.•....••...•••••....... 05-13-24 [SRSSS] ••......••...........••••• OS-13-43
IFLUID PUMP ASSEMBLY[SRSSS] ..... OS-13-26 OUTPUT SHAFT RING GEAR AND HUB
OVERDRIVE BRAKE AND COAST SHAFT COMPONENT
CLUTCH DRUM COMPONENT DISASSEMBLY/ASSEMBLY
DISASSEMBLY/ASSEMBLY [SR55S] .•......••.....•.....•••.. 05-13-48
[SRSSS] •...••••...•••..........• OS-13-30 FORWARD RING GEAR COMPONENT
INTERMEDIATE BRAKE AND DIRECT DISASSEMBLY/ASSEMBLY
CLUTCH DRUM COMPONENT [SRSSS] ••.....••.....••.....••... OS-13-49
DISASSEMBLY/ASSEMBLY LOW/REVERSE BRAKE SERVO
[SRSSS] •...••••...•••......•••.. OS-13-34 COMPONENT DISASSEMBLY/ASSEMBLY
FORWARD CLUTCH [SRSSS] .••••.•.........•.•....•.• OS-13-50
DISASSEMBLY/ASSEMBLY CONTROL VALVE BODY
[SRSSS] •....••.••...••.....••••. 05-13-39 DISASSEMBLY/ASSEMBLY
[SRSSS] ••••....•.....•••....••... OS-13-S4
AUTOMATIC TRANSMISSION ASSEMBLY
[SR5SS] .....•••..•...•....•••..•• OS-13-S7
05-13-1
AUTOMA:
AUTOMATIC TRANSM TIC TRANSMIS
Exploded View ISSION DlSASSEMBLYI5R55S] SION [5R55S]
id0513c1260100
b5r5za00000382
05-13-2
~
-~-
b5r5za00000383
05-13-3
148
b5r5za00000384 f;
Torque converter installation nut 6 Bolt and washer
2 Torque converter 7 Fluid pump cover
3 Input shaft 8 Fluid pump adapter plate
4 Fluid pump seal 9 Fluid pump gasket
5 Fluid pump seal ring 10 Seal ring
05-13-4
"..
AUTOMATIC TRANS MISSION [5R55S]
11 Stator support seal 66 Thrust bearing (No.7)

12 Fluid pump support 67 Forward planetary component
;) 13
14
O-ring
Fluid pump control valve
68
69
Input shell and sun gear component
Spacer
15 Fluid pump component 70 Retaining ring
16 Bolt 71 Lower/reverse planetary component
I.
17 Seal ring 72 Output shaft sleeve
18 Thrust washer (No.1) 73 Retaining ring
19 Intermediate and overdrive brake band anchor strut 74 Output shaft ring gear
20 Intermediate and overdrive brake band 75 Output shaft hub
21 Intermediate and overdrive brake band apply strut 76 Retaining ring
Intermediate and overdrive brake band adjusting 77 Output shaft hub seal
22
screw 78 Thrust bearing (No.10)
23 Locknut Low/reverse brake drum and one-way clutch
79
24 Overdrive brake drum component
25 Direct clutch and coast clutch piston outer seals 80 Low/reverse brake band
26 Direct clutch and coast clutch piston inner seals 81 Output shaft needle bearing
27 Direct clutch and coast clutch pistons 82 Thrust washer (No.11)
28 Direct clutch and coast clutch piston spring 83 Parking gear
29 Direct clutch and coast clutch piston spring retainer 84 Output shaft (4x2)
30 Retaining ring 85 Parking pawl
31 Coast clutch external spline plate (steel) 86 Parking pawl return spring
32 Coast clutch internal spline friction plate (friction) 87 Parking pawl shaft
33 Direct clutch and coast clutch pressure plate 88 Extension housing gasket
34 Retaining ring (select fit) 89 Extension housing (4x2)
35 Carrier adapter 90 Bolt (4x2)
36 Overdrive sun gear 91 Extension housing seal (4x2)
) 37 Overdrive planetary gear carrier component 92 Output shaft (4x4)
38 Thrust bearing (No.2) 93 Extension housing (4x4)
39 Overdrive ring gear 94 Extension housing seal (4x4)
40 Overdrive one-way clutch 95 Bolt (4x4)
41 Overdrive center shaft 96 Oil pipe connector component
42 Retaining ring 97 Retaining ring
43 Overdrive center shaft and ring gear component 98 Overdrive brake servo cover seal
44 Thrust bearing (No.3, No.5, NO.8 and No.9) 99 Overdrive brake servo cover
45 Retaining ring 100 Overdrive brake servo piston
46 Center support 101 Spring
47 Nut and cage component 102 Retaining ring
48 Bolt 103 Intermediate brake servo cover seal
49 Thrust bearing (No.4) 104 Intermediate brake servo cover
50 Intermediate brake drum 105 Intermediate brake servo piston
51 Direct clutch external spline plate (steel) 106 Transmission case
52 Direct clutch internal spline plate (friction) 107 TSS sensor, ISS sensor and OSS sensor
53 Forward clutch cylinder 108 O-ring
54 Forward clutch piston 109 Bolt
55 Forward clutch piston spring component 110 Vent tube (4x2)
,
56 Retaining ring 111 Low/reverse brake actuating lever
57 Forward clutch external spline plate (steel) 112 Low/reverse brake band actuating lever shaft
58 Forward clutch internal spline plate (friction) Pressure tap plug (pressure control solenoid C
113
59 Forward clutch pressure plate circuit)
60 Retaining ring (select fit) 114 Fluid fill plug
61 Thrust bearing (No.6A) 115. Manual shaft retaining pin
62 Thrust washer (No.6B) 116 Parking pawl actuating rod
63 Retaining ring 117 Manual shaft outer and inner nut
64 Forward ring gear hub 118 Manual valve inner lever
65 Forward ring gear 119 Manual shaft seal
05-13-5
i iWI
120 Manual shaft 141 Bolt

121 Digital transmission range (TR) sensor 142 Control valve body component
122
123
124
Bolt and washer
Manual shaft lever
Reverse brake servo component
143
144
145
O-ring
Solenoid body
Bolt
e
1
125 Reverse brake servo plate 146 Bolt

126 Spring 147 Transmission fluid filter
127 Reverse brake servo piston and seal 148 Transmission fluid pump gasket
128 O-ring 149 Magnet
129 Reverse brake servo cover 150 Bolt
130 Bolt 151 Transmission fluid pump
131 Control valve spring retainer 152 Drain plug
132 Spring 153 Bolt
133 Reverse brake servo check valve 154 Fluid level indicating plug (short hex)
134 Bolt 155 Overdrive brake and coast clutch drum component
135 Separating plate (bonded)
156 Intermediate brake and direct clutch drum
136 Lower control valve body component
137 Bolt 157 Forward clutch component
138 Bolt 158 Overdrive brake servo
139 Detent spring 159 Intermediate brake servo
140 Bolt
Disassembly
Note
• Tag and identify all parts during disassembly.
1. Place the transmission on a workbench.
Warning
• The torque converter is heavy, especially
when full of fluid.
arnffv00000559
2. Using the SSTs, remove the torque converter.
arnffv00000519
,
05-13-6
3. Remove the input shaft.
,
05 ;
4 Using the SST, install the transmissio.n into ~he
. bench with the torque converter housing facing
up.
arnffv00000520
5. Remove the sensors.

TSSSENSOR ISS SENSOR OSS SENSOR
b5r5za00000363
6. Remove the manual shaft lever.
MANUAL SHAFT
LEVER
b5r5za00000364
7. Remove the digital transmission range (TR)

sensor.
,
DIGITAL TR
SENSOR
arnffv00000521
05-13-7
8. Using the SST, remove the extension housing
-
seal. (4x2)
Caution
• The parking pawl, parking pawl return
spring and parking pawl shaft could fall
out during removal of the extension
housing.
arnffv00000522
9. Remove the extension housing. (4x2)
b5r5zaOOOOOOll
10. Using the SSTs, remove the extension housing

seal. (4x4)
Caution
• The parking pawl, parking pawl return
spring and parking pawl shaft could fall
out during removal of the extension
housing.
11. Remove the extension housing. (4x4)
Note
• 4x2 shown, 4x4 similar.
12. Remove the parking pawl component and discard

the gasket.
(1) Remove the parking pawl shaft.
(2) Remove the parking pawl.
(3) Remove the parking pawl return spring.
(4) Remove and discard the gasket.
Note
• The transmission fluid pan gasket is
reusable. Clean and inspect the gasket for
damage. If not damaged, the gasket should
be reused. b5r5zaOOOOOQ13
05-13-8
13. Remove the screws, transmission fluid pan and
gasket.
14. Remove the transmission fluid filter and seal

component and discard.
o o
15. Remove the detent spring.
Warning
• The upper and lower servo covers are
under spring tension. Use care when
removing the piston and cover
component. Failure to follow these
instructions can result in personal injury.
16. Remove the low/reverse brake servo component.
Caution
• Do not damage solenoid body connector
pins.
b5r5za00000017
17. Remove the solenoid body component by lifting

on the body and pushing the connector from the
other side of the case.
b5r5za00000018
05-13-9
,
18. Remove the main control valve body, separator
-
plate and gasket.
b5r5za00000019
19. Using the SST, remove the fluid pump seal.
Caution
• Failure to loosen the overdrive brake
band adjusting screw prior to pump
removal may cause damage to the pump
and overdrive brake band.
• Throw the locknut away. The locknut are
not reusable for assembly.
b5r5za00000295
20. Remove and discard the locknut, and loosen the

overdrive brake band adjusting screw.
21. Remove and tag the overdrive brake band anchor

strut for assembly.
Caution
• The screws are not reusable for
assembly. Discard the screws. If the
screws are reused, the housing may
become separated from the
transmission.
b5r5za00000022
22. Remove and discard the screws.
b5r5za00000023
05-13-10
24. Using the SST, remove the fluid pump.
Caution
• Servo cover is under spring tension.
25. Using the SST, remove the retaining ring and

overdrive brake servo cover.
26. Remove the overdrive brake servo piston and

spring.
27. Remove the screw.
b5r5za00000030
05-13-11
28. Compress the overdrive brake band and remove
-
the apply strut.
Note
• Tag and identify parts for reassembly.
Caution
• Identify the anchor and apply ends of the
overdrive brake band.
b5r5za00000031
29. Remove and inspect the overdrive brake band.

Check the following conditions for installing a new
band:
• Inspect for glazing.
• Inspect for missing friction material.
• Inspect for material flaking.
• Inspect for damage to the anchor pins.
Note
• The new overdrive brake band is dark in
color. This is a normal condition of the band.
Hairline cracks in the band are also
considered normal. Do not install a new
band based solely on the color.
30. Remove the overdrive brake and coast clutch

drum component.
Caution
• Do not bend the trigger wheel.
31. Remove the overdrive planetary gear carrier.
Note
• The thrust bearing (No.12) is in this
component.
b5r5za00000034
05-13-12
Remove the thrust bearing (No.2).
33. Remove the overdrive ring gear, overdrive one-

way clutch component and center shaft as an
assembly.
b5r5za00000036
34. Remove the thrust bearing (No.3).
Note
• Tag and identify the thrust bearing (No.3) for
assembly.
Caution
• The center support nut could fall into the
remaining assembly if not removed.
b5r5za00000038
36. Remove the nut and cage.
05-13-13
37. Remove the retaining ring.
-
b5r5za00000040
38. Remove the center support.
Note
• The center support is repaired as an
assembly. Any damage requires installing a
new component.
• When removing the center support, pull
evenly around the center support web.
39. Inspect the center support component for wear or

damage.
(1) Inspect the thrust surfaces for wear or
damage.
(2) Inspect the center support sealing surface. 2
(3) Inspect the fluid passage for blockage or
damage.
b5r5za00000042
40. Inspect the seal rings for damage.
••
/~----------==-
b5r5za00000043
41. Inspect the bearing for missing rollers or damage.
••
••
/~----------==-
b5r5za000000 44
05-13-14
42. Inspect the direct clutch feed hole for blockage or
damage.
(1) Rotate the center support bearing to locate
the direct clutch feed hole.
(2) Inspect the direct clutch feed hole for
blockage or damage.
05 -~~
:'I
b5r5za00000045
Note
• Tag and identify the thrust bearing (No.4).
Caution
• Failure to loosen the intermediate brake
band adjusting screw prior to pump
removal may cause damage to the pump
and intermediate brake band.
• Throw the locknut away. The locknut are
not reusable for assembly.
44. Remove and discard the locknut, and loosen the

intermediate brake band adjusting screw.
Caution
• Servo cover is under spring tension.
45. Using the SST, remove the retaining ring and

intermediate brake servo cover.
46. Remove the intermediate brake servo piston and

spring .
,
•
••
05-13-15
47. Remove and tag the intermediate brake band
-
anchor strut for assembly.
Caution
• Identify the anchor and apply ends of the
intermediate brake band.
Note
• The new intermediate brake band is dark in
b5r5za00000047
48. Remove and inspect the intermediate brake band.

Check the following conditions for installing a new
band:
• Inspect for glazing.
• Inspect for missing friction material.
• Inspect for material flaking.
• Inspect for damage to the anchor pins.
b5r5za00000048
49. Remove and tag the intermediate brake band

apply strut for assembly.
b5r5za00000049
b5r5za00000050
05-13-16
51. Remove the intermediate brake and direct clutch
drum component.
Note
• The thrust bearing (No.5) may come out with
the intermediate brake and direct clutch
drum.
52. Remove the thrust bearing (No.5), tag and

identify.
53. Remove the forward clutch cylinder.
Note
• The thrust bearing (No.6A) may come out
with the cylinder. Tag for reassembly.
54. Remove the thrust bearing (No.6A).
Note
• The thrust bearing (No.6A) may have come
out with the forward clutch cylinder.
55. Remove the forward ring gear and hub as an

assembly.
Note
the forward ring gear and hub component.
05-13-17
56. Remove the thrust washer (No. 68) from the
-
forward ring gear hub.
b5r5zaOOOOOOS6
Note
the forward ring gear and hub component.
58. Remove the forward planetary component.
59. Remove the input shell and sun gear component.
b5r5za00000059
60. Remove the spacer.
bSr5za000000 60
05-13-18
Note
63. Remove low/reverse planetary component.
b5r5za00000063
Note
b5r5za00000064
65. Using a small pick, remove the output shaft

sleeve.
Note
• Use slots located around the outside of the
sleeve.
Warning
• The output shaft may fall out after
removing the retaining ring. Failure to
follow these instructions may result in
personal injury. b5r5za00000065
05-13-19
Caution
-
• Discard the retaining ring. A new retaining ring must be used for assembly.
66. While holding the output shaft, remove and

discard the retaining ring.
b5r5za00000066
67. Remove the output shaft and park gear.
b5r5za00000074
68. Remove the output shaft thrust washer.
Note
• Tag and identify the thrust washer (No.11).
b5r5za00000075
69. Remove the output shaft ring gear and hub.
05-13-20
-70. Remove the thrust bearing (No.10).
Caution
• Do not pry on the outer edge of the case
or damage to the gasket sealing surface
could occur.
05 -)
71. Using a pair of vice grips, hold the flat spots on

the low/reverse brake band actuating lever shaft,
wiggle it back and forth and remove the low/
reverse brake band actuating lever shaft.
Note
• It may be necessary to grind flat spots on the
edges of the low/reverse brake band
actuating lever shaft in order to remove it. LOW/REVERS BRAKE
BAND ACTUATING
LEVER SHAFT
b5r5za00000389
72. Remove the low/reverse brake band actuating

lever component.
73. Remove the low/reverse brake drum and one-way

clutch component by rotating it clockwise.
Note
• The inner race of the rear one-way clutch is
not removable. It is repaired in the case.
74. Inspect the low/reverse brake drum component

and install a new low/reverse brake drum
3
component if damaged.
(1) Inspect the low/reverse brake drum sprags.
(2) Inspect the low/reverse brake drum rollers.
(3) Inspect the low/reverse brake drum.
Note
• The reverse one-way clutch is part of the
low/reverse brake drum component. Install a
new low/reverse brake drum as an assembly
only.
b5r5za00000072
05-13-21
75. Remove the low/reverse brake band.
-
Caution
• To avoid damage, make sure the wrench
does not strike the manual valve inner
lever pin.
b5r5zaOOOOO073
76. Remove the nut.
---~------
b5r5za00000076
77. Remove the manual shaft retaining pin.
b5r5za00000077
78. Remove the manual shaft.
---~<
~ \~~On~()~
b5r5za00000078
79. Disconnect the manual valve inner lever from the

parking lever actuating rod.
b5r5za000000 79
05-13-22
Remove the manual valve inner lever.
05 5
b5r5za00000080
81. Remove the parking lever actuating rod.
Caution
• Do not damage the bore.
82. Remove the manual shaft seal.
b5r5za00000082
05-13-23
FLUID PUMP D1SASSEMBLY[5R55S]
-
id0513C1262600
1. Remove the fluid pump gasket, fluid pump seal
ring and the No.1 thrust washer.
(1) Remove and discard the fluid pump gasket.
(2) Remove and discard the fluid pump seal ring
(square cut).
(3) Remove and tag the thrust washer (No.1).
b5r5za00000087
2. Remove the fluid pump support seal ring.
b5r5za00000088
3. Remove the seal rings.
b5r5za00000089
4. Remove the fluid pump support from the fluid

pump cover.
b5r5za00000423
•...
• '?
05-13-24
Remove the fluid pump gears.
Note
• A rough casting on the pump surface
crescent is not a flaw.
• The fluid pump gears are part of the pump
component and are not repaired separately.
6. Remove the drive gear seal ring and discard.

Inspect the fluid pump gears for cracks and
scoring.
b5r5za00000092
7. Inspect the overdrive pump.

• Inspect the overdrive pump support gear
pockets for scoring and wear.
• Clean and inspect the overdrive and rear
input shaft bushings.
b5r5za00000093
8. Inspect the fluid pump adapter plate for scoring

and wear.
b5r5za00000094
9. Remove and discard the fluid pump control valve.
b5r5za00000095
05-13-25
10. Inspect the fluid pump-to-converter housing
-
bushing.
b5r5za00000096
FLUID PUMP ASSEMBLV[5R55S]

Id0513c1262700
1. Inspect the fluid pump components for the following:
• Pump body and case for burrs
.• Fluid passages for obstructions
Note
• Minor burrs and scoring may be removed with crocus cloth. If damage is found, install a new assembly.
2. Install a new seal onto the SST.
Note
• Check and make sure that the garter spring
in the seal has not popped off of the
converter hub seal.
3. Using the SST, install the converter hub seal.

" .b5r5za00000097
b5r5za00000098
4. Install a new seal ring in fluid pump drive gear.
Caution
• Lubricate the SST with multi-purpose
grease.
b5r5za00000099 e
05-13-26
5. Using the SST, seat the O-ring in the pump gear.
Caution
• The chamber on the inside edge of the
small gear must be UP when in the pump
housing gear pocket. The dimple on the
larger gear must be DOWN when in the
pump housing gear pocket.
5:
1
05
1
b5r5za00000100
6. Install the pump gears into the fluid pump

housing. Apply multi-purpose grease to the pump
gear to prevent scoring at start up.
b5r5za00000101
7. Install a new O-ring on the new fluid pump control

valve.
bn
b5r5za00000102
8. Install a new valve with the tab facing down.
b5r5za00000103
9. First install the fluid pump adapter plate and then

the alignment pins in their correct location.
Caution
• The SST must be used to correctly align
the pump with the adapter plate to reduce
gear noise, bushing failure and leakage.
arnffv00000524
05-13-27
10. Using the SST, align the fluid pump to the adapter
plate.
b5r5zaOOOOO105
11. Using the SST, assemble the fluid pump.
arnffv00000525
12. Loosely install the fluid pump housing screws in

their correct location and remove the SSTs.
13. Install the 2 remaining screws and tighten all the

screws in a star pattern.
Tightening torque
22-28 N·m {2.3-2.8 kgf·m, 17-20 ft· Ibf}
arnffv00000527
14. Install a new fluid pump seal ring.
••
b5r5za00000109
05-13-28
15. Install the new seal rings.
Caution
• Be careful not to overstretch the seal ring
past the seal ring groove. Damage to the
seal will occur.
.-.
16. Using the SST, install the fluid pump seal ring.
Caution
• Verify correct seal installation.
b5r5za00000111
17. Verify that the seal is installed correctly.
Note
• Make sure seal grooves are clean and free
of burrs. Make sure that the seal is seated
into the groove.
Caution
• Failure to correctly size the seal will
cause damage to the seal when the
~torque converter is installed.
b5r5za00000112
18. Using the SST, size the seal to the correct size.
Leave the SST on the seal ring for 2 min to obtain
the correct seal size.
b5r5za00000113
05-13-29
OVERDRIVE BRAKE AND COAST CLUTCH DRUM COMPONENT DISASSEMBLY/ASSEMBLY[5R55S1
idO'!;13c1262100
Overdrive Brake and Coast Clutch Drum Component
b5r5za00000114
Overdrive brake drum 7 Retaining ring

2 Coast clutch piston outer seal ring 8 Coast clutch external spline plate (steel)
3 Coast clutch piston inner seal ring 9 Coast clutch internal spline plate (friction)
4 Coast clutch piston 10 Coast clutch pressure plate
5 Overdrive piston spring 11 Retaining ring (select fit)
6 Coast clutch piston spring retainer
Disassembly
1. Remove the coast clutch pressure plate.
(1) Remove the retaining ring.
(2) Remove the coast clutch pressure plate.
b5r5za00000115
••
2. Remove the coast clutch disc pack.
• Inspect for wear, install a new pack as
necessary.
•• ••
Warning
• Use caution when releasing tool pressure
on the piston spring. Failure to follow
••
these instructions may result in personal
injury.
e
Caution
• Do not fully compress the SST or damage
b5r5za00000116
to the spring retainer may occur.
05-13-30
3. Using the SST, remove the retaining ring.
4. Relieve the coast clutch spring tension and
remove the SST.
05 -
)
arnffv00000528
5. Remove the coast clutch piston springs.

(1) Remove the coast clutch piston spring
retainer.
(2) Remove the coast clutch piston springs.
Warning
• Air pressure must not exceed 138 kPa
{1.4 kgf/cm 2 , 20 psi}. Wear safety glasses
when using compressed air and make
sure the drum is facing down as shown.
Failure to follow these instructions may
result in personal injury. b5r5za00000118
6. Remove the coast clutch piston .

• Apply air pressure to the hole in the drum to
remove the coast clutch piston while blocking
the other hole with a finger.
b5r5za00000119
7. Remove and discard the coast clutch piston inner

seal and the coast clutch piston outer seal.
b5r5za00000120
Assembly
Caution
• The lip seals must be positioned as shown. Care must be taken to prevent rollover of the lip seal.
05-13-31
1. Install the new coast clutch piston inner and outer
seal.
b5r5za00000121
2. Verify the check ball is free to move.
Caution
• Care must be taken to prevent damage to
the seals during installation.
b5r5za00000122
3. Using the SST, install the coast clutch piston.

• Lubricate the seals with transmission fluid.
••
arnffv00000529
4. Install the coast clutch piston springs.

(1) Install the coast clutch piston springs.
(2) Install the coast clutch piston spring retainer.
Caution
to the coast clutch piston spring retainer
may occur.
b5r5za00000124
5. Using the SST, install the spring retainer ring.
Caution
• Coast clutch friction plates are
directional and must be installed with
grooves clockwise (10 to 00). The word
TOP should face up.
• If new clutch plates are being used, they
should be soaked in clean ATF before
assembly.
arnffv00000528
05-13-32
6. When installing friction plates, the word TOP
should face up. If reusing plates, grooves must be
installed clockwise. Install the coast clutch disc
pack.
05 -
)
b5r5za00000126
7. Install the 2 steel clutch plates and 2 friction

clutch plates in alternating order starting with a
steel clutch plate.
•• ••
Caution
• The retaining ring is select fit. •• ••
b5r5za00000127
8. Install the coast clutch pressure plate.

(1) Install the coast clutch pressure plate.
(2) Install the original retaining ring.
Warning
when using compressed air and make
sure drum is facing down as shown.
result in personal injury.
b5r5za00000128
9. Air check the assembly.

• Apply air pressure to the hole in the drum
while blocking the other hole with a finger.
b5r5za00000119
10. Check the coast clutch disc pack free play.

(1) Push down on the coast pressure plate. 1.3-2.0 mm
(2) Check clearance between the coast clutch
{0.051-0.079 in}
retaining ring and coast pressure plate.
Clearance should be 1.3-2.0 mm {0.051-
0.079 in}. If clearance is not within the
specification, install a correct coast clutch
retaining ring that will provide the correct free
play adjustment.
Coast clutch clearance

Standard: 1.3-2.0 mm {0.051-0.079 in} b5r5za00000129
05-13-33
Retaining ring size for coast dutch clearance
Thickness Diameter
mm in mm in
1.37 0.0539 130.1 5.122
1.73 0.0681 130.1 5.122
2.08 0.0819 130.1 5.122
2.44 0.0961 130.1 5.122
INTERMEDIATE BRAKE AND DIRECT CLUTCH DRUM COMPONENT DISASSEMBLY/ASSEMBLY[5R55S1

id0513cl:tS2200
Intermediate Brake and Direct Clutch Drum Component
5 6 7
b5r5za00000130 fj\
1 Intermediate brake drum 7 Retaining ring
2 Direct clutch piston outer seal ring 8 Direct clutch external spline plate (steel)
3 Direct clutch piston inner seal ring 9 Direct clutch internal spline plates (friction)
4 Direct clutch piston 10 Direct clutch pressure plate
5 Direct clutch piston spring (20 required) 11 Retaining ring (select fit)
6 Direct clutch piston spring retainer
Disassembly
Caution
• The retaining ring is a select fit. See assembly procedure if installation of new ring or clutch pack
is required.
1. Remove the retaining ring and the direct clutch

pressure plate.
(2) Remove the direct clutch pressure plate.
Caution
• Clutch plates are directional. Note the
direction of the grooves for installation.
b5r5za00000131
05-13-34
2. Remove the direct clutch disc pack.
• Inspect and install new friction plates if worn,
damaged or overheated.
• Measure and record the thickness of the steel
plates for assembly.
Warning
• After removing the retaining ring, use
care when releasing the pressure on the
springs. Failure to follow these
instructions may result in personal injury.
••
Caution
b5r5za00000132

4. Relieve the direct clutch spring tension and
remove the SST.
arnffv00000530
5. Remove the direct clutch piston spring retainer

and the direct clutch piston springs.
(1) Remove the direct clutch piston spring
retainer.
(2) Remove the direct clutch piston springs.
Warning
{1.4 kgflcm 2 , 20 psi}. Wear safety glasses
when using compressed air, and make
sure the drum is facing down as shown.
Failure to follow these instructions may b5r5za00000134
6. Using compressed air, remove the direct clutch

piston from the intermediate brake drum.
b5r5za00000135
05-13-35
7. Remove and discard the direct clutch piston inner
and outer seal.
(1) Remove and discard the direct clutch piston
inner seal ring.
(2) Remove and discard the direct clutch piston
outer seal ring.
• Clean the components as necessary.
b5r5za00000136
Assembly
Caution
• The lip seals must be positioned as shown. Care must be taken to prevent rollover of the lip seal.
1. Install the new direct clutch piston inner seal ring

and the direct clutch piston outer seal ring.
Note
• Use new seals to help prevent seal failures.
Caution
• Lubricate the direct clutch piston inner
and outer seal rings with clean ATF.
b5r5za00000137 _
2. Install the direct clutch piston into the SST.
b5r5za00000138
3. Inspect the clutch components for damage or

wear. Install new components as necessary.
• Inspect the drum surface for damage.
• Inspect the clutch piston bore and piston.
• Check the fluid passages for obstructions.
All fluid passages must be clean and free of
obstructions.
••
• Inspect the clutch plates for damage.
• Inspect the clutch springs.
• Verify the check ball is free to move.
b5r5za00000139
05-13-36
4. Carefully remove the direct clutch piston from the
SST.
Caution
the seals during installation.
5. Using the SST, install the direct clutch piston .

• Lubricate the seals with transmission fluid
before installing.
.....-
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6. Install the direct clutch piston springs and the

retainer.
Warning
• After removing the retaining ring, use
care when releasing the pressure on the
springs. Failure to follow these
••
instructions may result in personal injury.
Caution
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7. Using the SST, install the retaining ring.

8. Relieve the direct clutch spring tension and
remove the SST.
Caution
• The. direct clutch friction plates are
grooves pointing clockwise (10 to 00)
and the word TOP facing up.
• If new plates are used, they should be
soaked in clean ATF before assembly.
9. When installing friction plates, the word TOP

should face up. If reusing plates, grooves must be
installed clockwise. Install the direct clutch disc
pack.
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05-13-37
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10. Install the steel clutch plates and friction clutch
plates in alternating order starting with a steel
clutch plate.
&:
Caution
• The retaining ring is a select fit.
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11. Install the direct clutch pressure plate using the

original retaining ring.
Warning
••
when using compressed air, and make
sure drum is facing down as shown.
Note b5r5za00000144
• The direct clutch piston must apply with air
pressure and release when air is removed.
12. Air check the assembly.

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05-13-38
13. Push down on the direct clutch disc pack and
check the gap between the direct clutch retaining
ring and the direct clutch pressure plate with a
feeler gauge.
• If the specifications do not match, use a select
fit direct clutch retaining ring to match
specifications and verify with a feeler gauge.
Direct clutch clearance

Standard: 1.3-2.0 mm {0.051-0.079 in}
Retaining ring size for direct clutch clearance

Thickness Diameter
mm in mm in
1.37 0.0539 130.1 5.122
1.73 0.0681 130.1 5.122
2.08 0.0819 130.1 5.122
2.44 0.0961 130.1 5.122
FORWARD CLUTCH DISASSEMBLY/ASSEMBLY[5R55S]

id0513c1262300
Forward Clutch Component
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Retaining ring (select fit) 5 Retaining ring

2 Forward clutch pressure plate 6 Forward clutch piston spring component
3 Forward clutch internal spline plate (friction) 7 Forward clutch piston
4 Forward clutch external spline plate (steel) 8 Forward clutch cylinder
Disassembly
1. Remove the pressure plate.
(2) Remove the pressure plate.
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05-13-39
2. Remove the forward clutch disc pack.
• Inspect the forward clutch plates for wear,
damage or overheating.
Warning
e
.,,
>.·
• Use caution when releasing tool pressure

on the clutch piston springs. Failure to
follow these instructions may result in
personal injury. ••
Caution
• Do not fully depress the SST or damage
b5r5za00000148

4. Relieve the forward clutch spring tension and
remove the SST.
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5. Remove the forward clutch piston spring

component.
Warning
{1.4 kgf·m, 20 psi}. Wear safety glasses
when using compressed air. Make sure
the cylinder is facing down as shown.
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6. Remove the forward clutch piston.

(1) Place the forward clutch cylinder with forward
clutch piston facing down.
(2) Install the center support on the forward
o 0
.-
clutch cylinder.
(3) Apply air pressure to the left port of the center
support.
b5r5za00000 151
05-13-40
Assembly
1. Inspect the clutch components for damage or wear. Install new components as necessary.
• Check the fluid passages for obstructions. All fluid passages must be clean and free of obstructions.
• Inspect the clutch plates for damage.
• Inspect the clutch piston springs.
• Inspect the needle bearing and seal rings for damage.
• Check clutch hub thrust surfaces for damage.
• Check clutch plates for flatness and fit on the clutch hub serrations.
2. Inspect the forward clutch piston and seals. ,-----------------------,
Note
• If the seals on the forward clutch piston show
any signs of damage, a new forward clutch
piston will need to be installed.
b5r5za00000152
3. Inspect the forward clutch drum component.

(1) Inspect the forward clutch cylinder surfaces
for scores or burrs.
(2) Inspect the forward clutch piston for scores or 1
burrs.
(3) Verify the check ball is free to move in the
piston.
b5r5za00000153
4. Install the SST on the forward clutch piston.
Note
• The SST must be installed on the forward
clutch piston for a couple of minutes prior to
installing it into the forward clutch cylinder.
Caution
the seals.
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5. Using the SST, install the forward clutch piston

component into the forward clutch cylinder.
Note
• Lubricate the forward clutch piston inner and
outer seal with clean ATF.
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05-13-41
6. Install the forward clutch piston spring
component.
Caution
• Do not fully depress the clutch piston
spring compressor or damage to the
spring retainer may occur.
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7. Using the SST, install the spring retaining ring.
Caution
• The forward clutch friction plates are
grooves pointing counterclockwise.
• If new plates are used, they should be
soaked in clean ATF before assembly.
8. If reusing plates, grooves must be installed

counterclockwise. Install the direct clutch disc
pack.
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9. Install the steel clutch plates and friction clutch

plates in alternating order starting with a steel
clutch plate.
Caution
• The retaining ring is a select fit.
••
b5r5za00000148
05-13-42
10. Install the original selective retaining ring.
(1) Install the forward clutch pressure plate.
(2) Install the original selective retaining ring.
Warning
when using compressed air. Make sure
the cylinder is facing down as shown.
11. Air check the forward clutch piston.

(1) Place the forward clutch cylinder with forward
clutch piston facing down.
(2) Install the transmission center support on the
forward clutch cylinder. --
(3) Apply air pressure to the left port of the center
support.
b5r5za00000296
12. Check the forward clutch disc pack free play.

(1) Press down on the forward clutch disc pack.
(2) Using a feeler gauge, check the gap between
the forward clutch retaining ring and the
forward clutch pressure plate.
• If the clearance is not within
specifications, install the correct size
retaining ring.
Forward clutch clearance

Standard: 1.3-2.0 mm {0.OS1-0.079 in}
b5r5za00000158
Retaining ring size for forward clutch clearance
Thickness Diameter
mm in mm in
1.73 0.0681 141.45 5.65
2.08 0.0819 141.45 5.65
2.44 0.0961 141.45 5.65
OVERDRIVE PLANETARY GEAR AND ONE-WAY CLUTCH COMPONENT DISASSEMBLY/ASSEMBLyrSRSSSl

idO's13c126240~
Retaining ring
2 Overdrive center shaft
3 Overdrive ring gear
4 Thrust bearing (No.2)
5 Overdrive planetary gear carrier component
6 Overdrive sun gear
7 Carrier adapter
05-13-43
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Overdrive Center Shaft Component Disassembly
1. Remove the overdrive center shaft from the
overdrive ring gear. 1
(2) While rotating counterclockwise remove the
overdrive center shaft from the ring gear.
Note
• The overdrive one-way clutch is serviced
with the overdrive center shaft component.
Caution
• Do not remove the overdrive one-way
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clutch. Damage to the clutch may occur if
it is removed.
2. Clean and inspect the overdrive one-way clutch

and overdrive center shaft.
• Inspect for cracks in the roller cage and wear
on the roller clutch and the press fit of the
one-way clutch to the overdrive center shaft.
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3. Inspect the one-way clutch.

• Temporarily insert the overdrive planetary
gear carrier component into the one-way
clutch rollers for verification of the one-way
clutch.
• The planetary gear must rotate
counterclockwise and hold when rotated
clockwise.
• Remove the planetary gear carrier
component.
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Overdrive Center Shaft Component Assembly

1. Install the overdrive center shaft and one-way
clutch.
(1) Install the overdrive center shaft and one-way
clutch.
o
(2) Install the retaining ring.
b5r5za00000424
05-13-44
Overdrive Planetary Gear Component Disassembly
1. Before installing a planetary component, the shaft
retaining pins should be checked for adequate
staking. Check the pins and shafts in the
planetary assemblies for loose fit and/or complete
disengagement. Install a new planetary
component if necessary.
Note
• Individual parts of the planetary carriers are
not serviceable.
b5r5zaOOOOO 163
2. Inspect the pinion gears for damaged or

excessively worn teeth and for free rotation.
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3. Inspect the overdrive one-way clutch inner race

and the inner and outer races for scored or
damaged surface areas where the rollers contact
the races.
)
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4. Remove and inspect the No.2 overdrive planetary

thrust bearing on the nose of the overdrive
planetary gear carrier component.
b5r5za00000166
05-13-45
5. Remove the carrier adapter.
Note
• Inspect the sun gear for damaged or worn
teeth.
b5r5za00000167
6. Remove and inspect the overdrive sun gear.
Caution
• Do not attempt to remove the thrust
bearing (No.12) from behind the pinion
gears.
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7. Inspect the thrust bearing (No. 12) for damage.
b5r5za00000169
Overdrive Planetary Gear Component Assembly

1. Install the No.2 overdrive planetary thrust bearing.
Note
• Thoroughly clean all parts and blow dry with
moisture-free compressed air.
• Use petroleum jelly to hold the thrust
bearing (NO.2) in place.
b5r5za00000166
05-13-46
2. Install the overdrive planetary gear carrier into the
center shaft and overdrive.
Caution
• Make sure that the No.12 bearing is in
place in the overdrive planetary prior to
installing the overdrive sun gear.
3. Install the overdrive sun gear with the recessed

gear teeth facing toward the adapter.
Caution
• Adapter part number must not be visible
after installation.
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4. Install the carrier adapter.
Note
• Inspect the sun gear for damaged or worn
teeth.
)
b5r5za00000167
05-13-47
OUTPUT SHAFT RING GEAR AND HUB SHAFT COMPONENT DISASSEMBLY/ASSEMBLY[5R55S]
id0513c1264500
1 Retaining shaft ring gear

2 Center shaft hub
3 Retaining ring
4 Output shaft hub seal
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Disassembly
1. Inspect the output shaft ring gear and hub shaft component for damage.
• If repair is necessary, use the following procedure.
2. Remove the seal.
__t__
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3. Remove the output shaft ring gear from the output
~-~
shaft hub.
(2) Remove the output shaft ring gear.
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Assembly
1. Install the output shaft ring gear onto the output
~~
shaft hub.
(1) Install the output shaft ring gear.
~
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05-13-48
2. Install the seal.
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------
FORWARD RING GEAR COMPONENT DISASSEMBLY/ASSEMBLY[5R55S]
Id0513c1264900
Disassembly
1. Inspect the forward ring gear and hub component for damage.
• If repair is necessary, use the following procedure.
2. Remove the forward ring gear hub from the
forward ring gear. ~RETAINING
(2) Remove the forward ring gear hub.
'=--1) RING
FORWARD RING~9~
GEAR HUB ~
FORWARD
RING GEAR
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) Assembly
1. Install the forward ring gear hub onto the forward ring gear.
(1) Install the forward ring gear hub
05-13-49
LOW/REVERSE BRAKE SERVO COMPONENT D1SASSEMBLY/ASSEMBLY[5R55S]
id0513c1264600
~
~
r
10 N·m {102 kgf·cm, 89 in.lbf}
b5r5za00000360
1 Control valve spring retainer 5 Spring

2 Spring 6 Low/reverse brake servo piston and seal
3 Low/reverse brake servo check valve 7 O-ring
4 Low/reverse brake servo plate 8 Low/reverse brake servo cover
Disassembly
1. Remove the control valve spring retainer.
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2. Remove the low/reverse brake servo spring and

check valve.
Warning
separating the 2 halves. Failure to follow
these instructions can result in personal
injury.
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i
05-13-50 ~
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3. Remove the low/reverse brake servo plate by
turning in either direction to release.
• Align the arrow on the servo plate with any
slot on the cover.
Note
• Tabs on servo plate mate with slots on cover
every 120 degrees.
4. Remove the spring.
b5r5zaOOOOO 179
5. Remove the low/reverse brake servo piston and

seal component.
• Inspect the seal for damage, install a new low/
reverse brake servo piston if necessary.
b5r5za00000180
6. Remove and discard the low/reverse brake servo

piston seal.
b5r5za00000181
05-13-51
Assembly
1. Lubricate and install a new low/reverse brake
servo piston seal.
Note
• Try not to roll the seal onto the housing when
installing the seal, or damage to the seal can
occur.
b5r5za00000181
2. Lubricate and install the low/reverse brake servo

piston and seal component.
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3. Install the spring.
Warning
assembling the 2 halves. Failure to follow
these instructions can result in personal
injury.
Caution
• The arrow on the servo plate must be
aligned evenly between any 2 slots on the
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cover.
4. Install the low/reverse brake servo plate.
b5r5za00000182
05-13-52
5. Install the spring and low/reverse brake servo
check valve.
6. Install the control valve spring retainer.
Tightening torque
b5r5za00000176
05-13-53
CONTROL VALVE BODY DISASSEMBLY/ASSEMBLY[5R55S]
id0513c1261800
b5r5za00000083 I;'
1 Retainer clip 29 Retainer clip
2 Retainer plug 30 Reverse modulator valve
3 Thermo valve component 31 Reverse modulator valve spring
4 Fluid cooler bypass valve 32 Retainer clip
5 Fluid cooler bypass spring 33 Retainer plug
6 Retainer clip 34 Reverse engagement valve
7 Retainer plug 35 Reverse engagement valve spring
8 Converter clutch control valve spring 36 Retainer clip
9 Converter clutch control valve 37 Retainer plug
10 Plate 38 VFS1 modulator valve
11 Coast clutch control spring 39 VFS1 modulator valve spring
12 Coast clutch control valve 40 Retainer clip
13 Retainer clip 41 Sleeve
14 Retainer plug 42 Booster valve
15 Converter clutch back pressure valve 43 Booster valve
16 Converter clutch back pressure spring 44 Inner spring
17 Retainer clip 45 Outer spring
18 Retainer plug 46 Retainer spring
19 VFS2 modulator valve 47 Main regulator valve
20 VFS2 modulator valve spring 48 Retainer clip
21 Retainer clip 49 Retainer plug
22 Retainer plug 50 Converter limit spring
23 Intermediate servo release valve 51 Converter limit valve
24 Intermediate servo release valve spring 52 Plate
25 Plate 53 Solenoid regulator valve spring
26 High clutch control spring 54 Solenoid regulator valve
27 High clutch control Valve 55 Manual valve
28 Retainer plug 56 Retainer clip
05-13-54
57 Retainer plug 69 Overdrive servo control spring

58 Rear servo control valve spring 70 Overdrive servo control valve
59 Rear servo control valve 71 Clip retainer
60 Retainer clip 72 Converter clutch modulator control sleeve
61 Retainer plug 73 Converter clutch modulator control valve
62 RS ISA select valve spring 74 Converter clutch modulator valve
63 RS ISA select valve 75 Converter clutch modulator control spring
64 Retainer clip 76 Separator plate
65 Retainer plug 77 Lubrication check ball
66 Forward engagement control valve spring 78 Shuttle valve ball
67 Forward engagement control valve 79 Lower control valve body
68 Plate 80 Bolt
Disassembly
1. Remove and discard the separator plate.
Note
• The valve body separator plate has a
bonded gasket. Do not reuse. Discard the
plate.
b5r5za00000084
• 2. Remove the check balls.

)~ 3. Disassemble the control valve body only if
cleaning is required.
Note
• Refer to the disassembled view.
b5r5za00000085
Assembly
Caution
• Do not lose parts when cleaning or repairing.
1. Thoroughly clean all parts in solvent and blow dry with moisture-free compressed air.
Caution
• Do not stone, file or sand the valves. This will remove the anodized finish and may result in further
main control or transmission damage.
2. After cleaning the control valve body, carry out the following:
• Inspect all valve and plug bores for scoring or burrs
• Check all fluid passages for obstructions
• Inspect all valves and plugs for burrs
• Inspect all mating surfaces for burrs or distortion
• Inspect all springs for distortion
• Check all valves and plugs for free movement in their respective bores
- Valves and plugs, when dry, must fall from their own weight into their respective bores
• Roll the manual valve on a flat surface to check for a bent condition
3. Assemble the main control valve body.
05-13-55
4. Install the control valve body check balls.
b5r5za00000297
5. Using the SSTs, install a new separator plate.
Tightening torque
6-8 N·m {62-81 kgf·cm, 54-70 in·lbf}
Note
• Use a new valve body separator plate for
main control valve body installation.
arnflv00000523
05-13-56
AUTOMATIC TRANSMIS AUTOMATIC TRANSMISS
J
---~ ...
Exploded View . SION ASSEMBLYI5R55S1 ION [5R55S] id0513c1261900
................ """\
.-- '
.-_.-- I
I
I
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05-13-57
_.l'lv.
•
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05-13-58
b5r5za00000384
) ~:---T=To-rq-ue-c-o-nv-ert-:-e-ri:--ns-:-ta-::-lIa-:-:ti-on-n~ut:----------' P Bolt and washer

2 Torque converter 7 Fluid pump cover
3 Input shaft 8 Fluid pump adapter plate
4 Fluid pump seal 9 Fluid pump gasket
5 Fluid pump seal ring 10 Seal ring
05-13-59
11 Stator support seal 66 Thrust bearing (No.7)

12 Fluid pump support 67 Forward planetary component
13 O-ring 68 Input shell and sun gear component
14 Fluid pump control valve 69 Spacer
15 Fluid pump component 70 Retaining ring
16 Bolt 71 Lower/reverse planetary component
17 Seal ring 72 Output shaft sleeve
18 Thrust washer (No.1) 73 Retaining ring
19 Intermediate and overdrive brake band anchor strut 74 Output shaft ring gear
20 Intermediate and overdrive brake band 75 Output shaft hub
21 Intermediate and overdrive brake band apply strut 76 Retaining ring
Intermediate and overdrive brake band adjusting 77 Output shaft hub seal
22
screw 78 Thrust bearing (No.1 0)
23 Locknut Low/reverse brake drum and one-way clutch
79
24 Overdrive brake drum component
25 Direct clutch and coast clutch piston outer seals 80 Low/reverse brake band
26 Direct clutch and coast clutch piston inner seals 81 Output shaft needle bearing
27 Direct clutch and coast clutch pistons 82 Thrust washer (No.11)
28 Direct clutch and coast clutch piston spring 83 Parking gear
29 Direct clutch and coast clutch piston spring retainer 84 Output shaft (4x2)
30 Retaining ring 85 Parking pawl
31 Coast clutch external spline plate (steel) 86 Parking pawl return spring
32 Coast clutch internal spline friction plate (friction) 87 Parking pawl shaft
33 Direct clutch and coast clutch pressure plate 88 Extension housing gasket
34 Retaining ring (select fit) 89 Extension housing (4x2)
35 Carrier adapter 90 Bolt (4x2)
36 Overdrive sun gear 91 Extension housing seal (4x2)
37 Overdrive planetary gear carrier component 92 Output shaft (4x4)
38 Thrust bearing (No.2) 93 Extension housing (4x4)
39 Overdrive ring gear 94 Extension housing seal (4x4)
40 Overdrive one-way clutch 95 Bolt (4x4)
41 Overdrive center shaft 96 Oil pipe connector component
42 Retaining ring 97 Retaining ring
43 Overdrive center shaft and ring gear component 98 Overdrive brake servo cover seal
44 Thrust bearing (No.3, No.5, No.8 and No.9) 99 Overdrive brake servo cover
45 Retaining ring 100 Overdrive brake servo piston
46 Center support 101 Spring
47 Nut and cage component 102 Retaining ring
48 Bolt 103 Intermediate brake servo cover seal
49 Thrust bearing (No.4) 104 Intermediate brake servo cover
50 Intermediate brake drum 105 Intermediate brake servo piston
51 Direct clutch external spline plate (steel) 106 Transmission case
52 Direct clutch internal spline plate (friction) 107 TSS sensor, ISS sensor and OSS sensor
53 Forward clutch cylinder 108 O-ring
54 Forward clutch piston 109 Bolt
55 Forward clutch piston spring component 110 Vent tube (4x2)
56 Retaining ring 111 Low/reverse brake actuating lever
57 Forward clutch external spline plate (steel) 112 Low/reverse brake band actuating lever shaft
58 Forward clutch internal spline plate (friction) Pressure tap plug (pressure control solenoid C
113
59 Forward clutch pressure plate circuit)
60 Retaining ring (select fit) 114 Fluid fill plug
61 Thrust bearing (No.6A) 115 Manual shaft retaining pin
62 Thrust washer (No.6B) 116 Parking pawl actuating rod
63 Retaining ring 117 Manual shaft outer and inner nut
64 Forward ring gear hub 118 Manual valve inner lever
65 Forward ring gear 119 Manual shaft seal
05-13-60
120 Manual shaft 141 Bolt

121 Digital transmission range (TR) sensor 142 Control valve body component
122 Bolt and washer 143 O-ring
123 Manual shaft lever 144 Solenoid body
124 Reverse brake servo component 145 Bolt
125 Reverse brake servo plate 146 Bolt
126 Spring 147 Transmission fluid filter
127 Reverse brake servo piston and seal 148 Transmission fluid pump gasket
128 O-ring 149 Magnet
129 Reverse brake servo cover 150 Bolt
130 Bolt 151 Transmission fluid pump
131 Control valve spring retainer 152 Drain plug
132 Spring 153 Bolt
133 Reverse brake servo check valve 154 Fluid level indicating plug (short hex)
134 Bolt 155 Overdrive brake and coast clutch drum component
135 Separating plate (bonded) 156 Intermediate brake and direct clutch drum
136 Lower control valve body component
137 Bolt 157 Forward clutch component
138 Bolt 158 Overdrive brake servo
139 Detent spring 159 Intermediate brake servo
140 Bolt
Assembly
1. Thoroughly clean the transmission case and extension housing in solvent and blow dry with compressed air.
2. Inspect the transmission case for the following:
• Stripped bolt hole threads
• Gasket and mating surfaces for burrs or nicks
• Obstructions to vent and fluid passages
• Cracks or warpage
b5r5zaOOOOO 186
3. Inspect the extension housing for cracks, burrs or

warpage.(4x2)
b5r5za00000187
05-13-61
4. Inspect the extension housing for cracks, burrs or
warpage. (4x4)
b5r5za00000188
5. Inspect the case bearing for damage. If damage

to the case bearing is indicated, install a new
case.
Warning
• Make sure the lockpin on bench-mounted
holding fixture is secure. Failure to follow
these instructions may result in personal
injury.
b5r5za00000189
6. Using the SST, install the transmission into the

bench with the converter housing facing up.
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7. Using the SST, install the manual shaft seal and

lubricate it with petroleum jelly.
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8. Install the parking lever rod.
b5r5za00000192
05-13-62
9. Install the manual control lever.
10. Assemble the manual valve inner lever and

parking lever actuating rod as shown.
Caution
• Align the flats on the manual valve inner
lever with the flats on the manual shaft.
b5r5za00000194
11. Install the manual shaft.
___ ~1 ~
~ \~~on~n~
b5r5za00000195
12. Install the manual valve inner lever onto the

manual shaft and loosely install the nut.
Caution -::=====~ 0
• Use care not to damage the transmission
fluid pump rail surface when installing
the retaining pin.
b5r5za00000196
13. Install the manual shaft retaining pin.

• Tap the manual shaft retaining pin into the
transmission case.
Note
• Align the manual shaft alignment groove with
the manual shaft retaining pin bore in the
) transmission case.
Caution
• To avoid damage, do not allow the
wrench to strike the manual valve inner b5r5zaOOOOO 197
lever pin.
05-13-63
14. Tighten the nut.
Tightening torque
41-54 N·m {4.2-5.5 kgf·m, 31-39 ft.lbf}
Caution
• Make sure band is resting on the 2
anchor pins in the case.
15. Install the low/reverse brake band.
16. Install the low/reverse brake drum and one-way

clutch component.
• Rotate the low/reverse brake drum clockwise
to install.
b5r5za00000388
17. Install the low/reverse brake band actuating lever

into the low/reverse brake band.
Note
• The reverse band actuating lever must fit
into the notches in the band.
18. Install the low/reverse brake band actuating lever

shaft into the case and into the low/reverse brake
band actuating lever.
LOW/REVERS BRAKE
BAND ACTUATING
LEVER SHAFT
b5r5za00000389
05-13-64
19. Install the thrust bearing (No.10) into the case.
Caution
• Do not damage the seal against the case
during assembly.
20. Install the output shaft ring gear, hub and seal.
Caution
• The tabs on the output shaft thrust
washer (No.11) point into the case. Make
sure the thrust washer is correctly
seated.
21. Install the output shaft thrust washer (No.11).

• Coat the output shaft thrust washer with
petroleum jelly.
b5r5zaOOOOO 199
22. Install the park gear on the output shaft.
b5r5za00000200
23. Install the output shaft and park gear.
Caution
• Always install a new retaining ring.
b5r5za00000201
05-13-65
24. Install a new retaining ring.
b5r5za00000208 .
25. Install the output shaft sleeve.
Note
• Install the output shaft sleeve with the cone
facing up. This sleeve will snap into place
when correctly installed.
26. Install the thrust bearing (No.9) onto the output

shaft ring gear and hub component.
Caution
• Make sure the needle bearings stay in
place.
b5r5za00000210
27. Install the low/reverse planetary component.
Caution
• The low/reverse brake drum must be
pulled forward to install the retaining
ring.
b5r5za00000211
b5r5za00000212
05-13-66
29. Install the thrust bearing (No.8).
30. Install the spacer on the input shell, using

petroleum jelly to hold it in place.
b5r5za00000214
31. Install the input shell and sun gear component.
32. Install the forward planetary component.
Note
• The bearing (No.13) must be correctly
seated in the forward planet component so
the sun gear can be installed correctly.
b5r5za00000216
33. Install the thrust bearing (No.7) into the forward

ring gear and hub component. Use petroleum jelly
to hold the bearing in place.
05-13-67
34. Install the thrust washer (No.68) onto the forward
ring gear hub.
b5r5za00000218
35. Install the forward ring gear and hub as an

assembly.
36. Install the thrust bearing (No.6A) into the forward

ring gear and hub.
37. Install the forward clutch cylinder.
b5r5za00000222
05-13-68
39. Install the intermediate brake servo piston and
spring.
• Lubricate the servo bore with clean ATF.
40. Using the SST, install the intermediate brake

servo cover and retaining ring.
41. Install the intermediate brake and direct clutch

drum component.
42. Using a depth micrometer with an appropriate

length extension, measure from the top of the
gauge bar to the center support ledge in the case
at 4 places 90 degrees apart.
• Add the 4 measurements, divide by 4 and
record as dimension A.
Caution
• The torque specifications are critical for
this procedure. Failure to use the correct
torque specifications may cause
transmission damage.
b5r5za00000226
43. Install the SST.

(1) Install the SST and the bolts using the 2 pump
bolt locations at approx. 6 and 12 o'iock
positions.
Tightening torque
15 N·m {1.5 kgf·m,11 ft.lbf}
(2) Tighten the center bolt.
Tightening torque
1.13 N·m {11.5 kgf.cm,10.0 in·lbf}
05-13-69
44. Measure the distance from the top of the gauge
bar to the drum bearing surface through the hole
in the disc and record as dimension B. Repeat the
measurement 180 degrees on the opposite side
of the SST and record as dimension C.
Note
• Align the disc holes on SST with the slot in
gauge bar for correct measurement.
45. Add dimension B to C, divide by 2 and record as

dimension D.
b5r5za00000228
46. Subtract A from D and record as dimension E.
47. Select the bearing from the following chart, using
dimension E.
,I'
I,
Thrust bearing (No.4) size (intermediate brake drum)
Dimension E Bearing Thickness Identification (Notches)
1.69-1.87 mm {0.066-O.074 in} 2.65-2.80 mm {0.1 04-0.11 0 in} None
1.88-2.04 mm {0.073-O.080 in} 2.83-2.98 mm {0.111-0.116 in}
2.05-2.22 mm {0.081- 0.088 in} 3.01-3.16 mm {0.118-0.124 in} 2
2.23-2.43 mm {0.088-O.096 in} 3.21-3.36 mm {0.126-0.132 in} 3
48. Install the intermediate brake band.
Note
• Make sure that the intermediate brake band
apply strut is aligned with the band notch.
• If the intermediate brake band is reused, it
must be installed in the same position as it
was when removed.
• The new intermediate brake band is dark in
b5r5za00000229
Caution
• To avoid a fall out condition of the strut from the screw during assembly and function, the small U-
shaped notch should be toward the band and the large U-shaped notch toward the main control
side.
05-13-70
49. Install the intermediate brake band anchor strut.
(1) Band/case side of anchor (small U notch).
(2) Main control side of anchor (large U notch).
)
Caution
• If the strut is installed incorrectly,
transmission damage will occur.
b5r5za00000230
50. Check to make sure that the intermediate brake

band anchor strut is installed in the correct
orientation to the case and adjustment screw.
b5r5za00000231
51. Loosely install the screw.
b5r5za00000232
52. Install the intermediate brake band apply strut.
Caution
05-13-71
53. Check to make sure that the intermediate brake
band apply strut is installed in the correct
orientation to the case and piston rod.
b5r5za00000234
54. Install the selected thrust bearing (No.4) on the

direct clutch drum.
• Coat the thrust bearing with petroleum jelly.
55. Install the center support.
Note
• Align the center support bolt hole with
correct case hole.
56. Install the nut and cage.
57. Loosely install the bolt.
Caution
• Install the retaining ring with the tapered
side facing up.
• Make sure the notch opening is not
obstructed by the retaining ring.
b5r5za00000238
05-13-72
(1) Make sure the retaining ring is installed with
the tapered side facing up.
(2) Make sure the opening of the retaining ring is
positioned correctly.
b5r5za00000239
60. Install the overdrive ring gear, overdrive one-way

clutch and center shaft component.
Caution
• Do not bend the trigger wheel. Make sure
that the thrust bearing (No.2) is in this
assembly.
61. Install the overdrive planetary gear carrier.
05-13~73
62. Install the overdrive brake and coast clutch drum
component.
b5r5za00000243
63. Install the overdrive brake servo piston and

spring.
• Lubricate the servo bore with clean ATF.
64. Using the SST, install the overdrive brake servo

cover and retaining ring.
65. Install the overdrive brake band.
Note
• If the overdrive brake band is reused, it must
be installed in the same position as when
removed.
• Make sure that the overdrive brake band
apply strut is aligned with the band notch.
• The new overdrive brake band is dark in
Caution
• To avoid a fall out condition of the strut from the screw during assembly and function, the small U-
shaped notch should be toward the band and the large U-shaped notch toward the main control
side.
05-13-74
66. Install the overdrive brake band anchor strut.
(1) Band/case side of anchor (small U notch).
(2) Main control side of anchor (large U notCh).
Caution
b5r5za00000298
67. Check to make sure that the overdrive brake band

anchor strut is installed in the correct orientation
to the case and adjustment screw.
b5r5za00000231
68. Loosely install the screw.
69. Install the overdrive brake band apply strut.
Caution
b5r5za00000248
05-13-75
70. Check to make sure that the overdrive brake band
apply strut is installed in the correct orientation to
the case and piston rod.
Caution
• The torque specifications are critical for
this procedure. Failure to use the correct
torque specifications may cause
transmission damage.
b5r5za00000249
71. Install the SST.

(1) Install the SST and the bolts using the 2 pump
bolt locations at approx. 6 and 12 o'iock
positions.
Tightening torque
15 N·m {1.5 kgf·m, 11 ft.lbf}
(2) Tighten the center bolt.
Tightening torque
1.13 N·m {11.5 kgf·cm, 10.0 in.lbf}
b5r5za00000250
72. Measure the distance from the top of the gauge

bar to the drum bearing surface through the hole
in the disc and record as dimension A. Repeat the
measurement 180 degrees on the opposite side
of the SST and record as dimension B.
Note
• Align the disc holes on SST with the slot in
gauge bar for correct measurement.
73. Add dimension A to B, divide by 2 and record as

dimension C.
b5r5za00000251
74. Subtract the thickness of the gauge bar 17.78
mm {0.70 in} from dimension C and record as
dimension D.
75. Select the thrust washer (No.1) from the following chart using dimension D.
Thrust washer (No.1) size (overdrive brake drum) .

Dimension E Bearing Thickness Identification (ColorIlD)
38.05-38.13 mm {1.50 in} 1.55-1.60 mm {0.061-0.063 in} White
38.14-38.28 mm {1.50-1.51 in} 1.75-1.80 mm {0.069-0.071 in} Green
38.29-38.42 mm {1.51 in} 1.85-1.90 mm {0.073-0.075 in} Red
38.43-38.61 mm {1.51-1.52 in} 2.05-2.10 mm {0.081-0.083 in} Black
38.63-38.74 mm {1.52-1.53 in} 2.15-2.20 mm {0.095-0.097 in} Yellow
76. Install the selected thrust washer (No.1).

• Coat the thrust washer with petroleum jelly.
b5r5za00000252
05-13-76
77. Install the SSTs into the transmission case.
78. Install the pump gasket.
Caution
• Make sure that the fluid pump inlet thrust
washer (No.1), selective thrust washer,
fluid pump gasket and the fluid pump-to-
case O-ring remain in the correct position
throughout this step.
b5r5za00000254
79. Install the fluid pump.
Caution
• The special tools must be used to
correctly align the pump with the adapter
plate to reduce gear noise, bushing
failure and leakage.
80. Using the SST, align the fluid pump to the adapter
plate.
81. Install the 6 screws. Tighten the screws in a star

pattern.
Tightening torque
22-28 N·m {2.3-2.8 kgf.m, 17-20 ft.lbf}
05-13-77
82. Remove the SSTs and install the 2 remaining
screws.
Tightening torque
22-28 N·m {2.3-2.8 kgf·m, 17-20 ft·lbf}
Caution
• Do not allow overdrive brake band
adjustment screw to back out. Band strut
could fall out of position.
• Install, but do not tighten, a new locknut
on the band adjustment screw. Apply
petroleum jelly to the locknut seal.
83. Install a new locknut on the band adjustment

screw.
Caution
• The overdrive servo must be installed
prior to band adjustment.
b5r5za00000259
84. Using the SST, tighten the intermediate brake

band adjustment screw.
Tightening torque
12-14 N·m {123-142 kgf·cm, 107-123
in·lbf}
• Then back off the screw exactly 2 turns and

hold that position.
85. Tighten the locknut.

(1) Hold the overdrive brake band adjustment
screw stationary.
(2) Tighten the locknut.
Tightening torque
47-61 N·m {4.8-6.2 kgf·m, 35-44 ft·lbf}
Caution
• Do not allow the intermediate brake band
adjusting screw to back out. Band strut '
could fall out of position.
b5r5za00000261
• Install, but do not tighten, a new locknut
on the band adjustment screw. Apply
petroleum jelly to the locknut seal.
05-13-78
86. Install a new locknut on the baM adjustment
screw.
Caution
• The intermediate brake servo must be
installed prior to band adjustment.
87. Using the SST, tighten the overdrive brake band

adjustment screw.
Tightening torque
12-14 N·m {123-142 kgf·cm, 107-123
in·lbf}
• Then back off the screw exactly 2 turns and

hold that position.
88. Tighten the locknut. .

(1) Hold the intermediate brake band adjustment
screw stationary.
(2) Tighten the locknut.
Tightening torque
47-61 N·m {4.8-6.2 kgf.m, ~5-44 ft.lbf}
b5r5za00000264
89. Tighten the center support bolt.
Tightening torque
9-13 N·m {92-132 kgf·cm, 80-115 in·lbf}
90. Using the SSTs, Carry out the air pressure test
procedure.
0 0
0
o 0
0 0
0
0 o 0
0 0
0 0 0
,0 0 0 0
0
arnffv00000541
05-13-79
II
II
I AUTOMATIC TRANSMISSION [5R55S]

II 91. Install the SSTs into the transmission case.
I!
1j
Ir
ii!l
!'
'I
i
arnffv00000542
92. Using the SSTs, Install the control valve body and
loosely install the bolts.
(1) Install the short bolt.
(2) Install the bolt with the larger head.
(3) Install the remaining bolts.
93. Remove the SSTs and loosely install the screw.
05-13-80
94. Tighten the bolts in the sequence shown.
Tightening torque
t 9-11 N·m {92-112 kgf·cm, 80-97 in·lbf}
b5r5za00000270
95. With the manual lever in the N position, install the

detent spring.
Tightening torque
9-11 N·m {92-112 kgf·cm, 80-97 in·lbf}
96. Install new O-rings on the solenoid body

connector. Lubricate the O-rings with clean ATF.
Caution
• Inspect the transmission case bore to
make sure it is free of foreign material
and not damaged. If damaged,
transmission leak may occur.
b5r5za00000272
05-13-81
97. Install the solenoid body. Tighten bolts in the
sequence shown.
Tightening torque
7-9 N·m {72-91 kgf·cm, 62-79 in·lbf}
)
b5r5za00000273
98. Install the reverse servo. Tighten the bolts in the

sequence shown in 2 stages.
Tightening torque
5 N·m {51 kgf·cm, 44 in·lbf}
10-12 N·m {102-122 kgf·cm, 89-106
in·lbf}
Caution
• Lubricate the transmission fluid filter
seals with clean ATF or they may be
damaged.
b5r5za00000274
99. Lubricate the seals and install the transmission

fluid filter.
Tightening torque
9-11 N·m {92-112 kgf·cm, 80-97 in.lbf}
f)
Note
• Make sure that the transmission fluid filter
seals are correctly seated on the filter.
1OO.lnstali the transmission fluid pump and gasket,

magnet and loosely install the bolts.
Note
• The transmission fluid pump gasket is
reusable. Clean and inspect for damage. If
not damaged, the gasket should be reused.
101.Tighten the bolts in a crisscross sequence.
Tightening torque
9.5-11.5 N·m {97-117 kgf·cm, 85-101
in·lbf}
05-13-82
102.lnstall the parking pawl component and gasket.
(1) Install the parking pawl shaft.
(2) Install the parking pawl return spring.
(3) Install the parking pawl.
(4) Install a new gasket.
103.1nstall the extension housing.(4x2)
Tightening torque
28-32 N·m {2.9-3.2 kgf.m, 21-23 ft.lbf}
b5r5za00000278
,
104.Using the SST, install the extension housing
seal. (4x2)
arnffv00000545
105.lnstall the extension housing.(4x4)
Tightening torque
28-32 N·m {2.9-3.2 kgf·m, 21-23 ft·lbf}
106.Using the SST, install the extension housing

seal. (4x4)
Caution
• The digital TR sensor must fit flush
against the boss on the case to prevent
damage to the switch.
b5r5za00000280
05-13-83
107.1nstall the digital TR sensor and loosely install the
bolts.
Caution
• Tightening one bolt before tightening the
other may cause the sensor to bind or
become damaged.
DIGITAL TR
SENSOR
arnffv00000521
1OB.Using the SST, align the digital TR sensor and

tighten the bolts in an alternating sequence.
Tightening torque
6.5-9.5 N·m {67-96 kgf·cm, 58-84 in·lbf}
Note
• The manual lever must be in the N position.
109.1nstall the manual shaft lever.

J
Tightening torque
41-54 N·m {4.2-5.5 kgf·m, 31-39 ft·lbf} arnffv00000592
Caution
• The splines of the input shaft are not the
same length on both ends. The shaft end
with the shorter splines goes into the
fluid pump.
MANUAL SHAFT
LEVER
b5r5za00000394
110.1 nstall the in put shaft.
05-13-84
111.Using the SST, make sure that the fluid pump
gear seal ring is fully seated.
112.Remove the SST.
Caution
• Do not damage the fluid pump gear 0-
ring when installing torque converter.
• Make sure the converter hub is fully
engaged in the pump support and gear
and rotates freely. Do not damage the
hub seal.
• If the torque converter slides out, the hub
seal may be damaged.
,
113.Lubricate the converter hub with clean ATF.
Warning
• The torque converter can fall out if the
transmission is tipped. Failure to follow
these instructions may cause personal
injury.
/? n n \\
b5r5za00000286
114.Using the SST, install the torque converter by

pushing and rotating.
115.Lubricate the torque converter pilot hub with

multi-purpose grease.
b5r5za00000288
, , 05-13-85
116.Using one of the sensor holes, fill the
transmission with 8.5 L {g.O US qt, 7.5 Imp qt} of
ATF.
Note
• Inspect O-rings for damage. Install new 0-
rings if damaged. Lubricate the O-rings with
petroleum jelly to prevent damage to the 0-
rings.
b5r5za00000291
117.lnstall the sensors.

TSS SENSOR ISS SENSOR OSS SENSOR
Tightening torque
TSS sensor, ISS sensor:
8-12 N·m
{82-122 kgf·cm, 71-106 in.lbf}
OSS sensor:
12-16 N·m
{123-163 kgf.cm, 107-141 in.lbf}
b5r5za00000396
118.1nstall the SST.
TORQUE
CONVERTER
05-13-86
TECHNICAL DATA [SRSSS]
05-50 TECHNICAL DATA [5R55S]

e TECHNICAL DATA[5R55S) ........... 05-50-1
TECHNICAL DATA[5R55S)
id0550h 1800500
Item Specification
Type: Mercon® V
ATF
Capacity (Approx. quantity): Refer to Repair Manual.
Coast clutch clearance Standard: 1.3-2.0 mm {0.051-0.079 in}
Direct clutch clearance Standard: 1.3-2.0 mm {0.051-0.079 in}
Forward clutch clearance Standard: 1.3-2.0 mm {0.051-O.079 in}
Retaining ring size for coast clutch clearance

Thickness Diameter
mm in mm in
1.37 0.0539 130.1 5.122
1.73 0.0681 130.1 5.122
2.08 0.0819 130.1 5.122
2.44 0.0961 130.1 5.122
Retaining ring size for direct clutch clearance

Thickness Diameter
mm in mm in
1.37 0.0539 130.1 5.122
1.73 0.0681 130.1 5.122
2.08 0.0819 130.1 5.122
2.44 0.0961 130.1 5.122
Retaining ring size for forward clutch clearance

Thickness Diameter
mm in mm in
1.73 0.0681 141.45 5.65
2.08 0.0819 141.45 5.65
2.44 0.0961 141.45 5.65
Thrust bearing (No.4) size (intermediate brake drum)

Dimension E Bearing Thickness Identification (Notches)
1.69-1.87 mm {0.066-0.074 in} 2.65-2.80 mm {0.104-0.110 in} None
1.88-2.04 mm {0.073-0.080 in} 2.83-2.98 mm {0.111-0.116 in}
2.05-2.22 mm {0.081- 0.088 in} 3.01-3.16 mm {0.118-0.124 in} 2
2.23-2.43 mm {0.088-0.096 in} 3.21-3.36 mm {0.126-0.132 in} 3
Thrust washer (No.1) size (overdrive brake drum)

Dimension E Bearing Thickness Identification (Color/ID)
38.05-38.13 mm {1.50 in} 1.55-1.60 mm {0.061-0.063 in} White
38.14-38.28 mm {1.50-1.51 in} 1.75-1.80 mm {0.069-O.071 in} Green
38.29-38.42 mm {1.51 in} 1.85-1.90 mm {0.073-0.075 in} Red
38.43-38.61 mm {1.51-1.52 in} 2.05-2.10 mm {0.081-0.083 in} Black
38.63-38.74 mm {1.52-1.53 in} 2.15-2.20 mm {0.095-O.097 in} Yellow
05-50-1
TECHNICAL DATA [S1SM-D, S1SMX-D]
05-50B TECHNICAL DATA [S15M-D, S15MX-D]

e TECHNICAL DATA
[S15M-D, S15MX-D] ............... 05-508-1
TECHNICAL DATA [S15M-D, S15MX-D]

DCF055000000W05
Item Specification
Standard clearance between shift fork and clutch hub
0.05-0040 mm {0.002-0.015 in}
sleeve groove
Maximum clearance between shift fork and clutch hub
0.5 mm {0.020 in}
sleeve groove
Standard clearance between synchronizer ring and
1.5 mm {0.059 in}
flank surface of gear
Maximum clearance between synchronizer ring and 0.8 mm {0.031 in}
flank surface of gear
Detent ball springs for 1st/2nd and 3rd/4th shift rods Standard length: 22.5 mm {0.886 in}
Detent ball spring for 5th/reverse shift rod Standard length: 24.97 mm {0.9831 in}
1st/2nd select lock spindle spring [4x2] Standard length: 57.5 mm {2.26 in}
Push pin spring for 1st/2nd shift rod end [4x4] Standard length: 32.8 mm {1.29 in}
Push pin spring for 5th/reverse shift rod end [4x4] Standard length: 41.0 mm {1.61 in}
Detent ball spring for 5th/reverse shift rod end [4x4] Standard length: 24.97 mm {0.9831 in}
Mainshaft maximum runout 0.03 mm {0.0012 in}
Standard clearance between shift rod end and control
lever 0.5 mm {0.020 in} or less
3rd/4th clutch hub end play 0-0.05 mm {0.0-0.0019 in}
Maindrive gear shaft total end play 0.05-0.15 mm {0.002-0.0059 in}
I ~C_o~u=n_te_rs_h_a_ft~to-ta~l~e~n~d~p-la~y~--------------~--------____o_.1~5~0~.2~5~m--m~{~0.~0-06---0~.0~09~8~in~}----------~
5th/Reverse clutch hub end play
Reverse gear end play
0-0.05 mm {0.0-0.0019 in}
0.25-0.35 mm {0.002-0.0059 in}
Reverse idler gear end play 0.1-0.2 mm {0.0040-0.0078 in}
3rd/4th clutch hub retaining ring

Thickness (mm {in})
1.50 {0.0591}
1.55 {0.061 O}
1.60 {0.0630}
1.65 {0.0650}
1.70 {0.0669}
1.75 {0.0689}
1.80 {0.0709}
1.85 {0.0728}
1.90 {0.0748}
1.95 {0.0768}
,
05-508-1
-,
I'
TECHNICAL DATA [S1SM-D, S1SMX-D]

Maindrive gear bearing shim selective chart
1.45-1.55
1.4 {0.055}
{0.0571-0.0610}
1.55-1.65
1.5 {0.059}
{0.0611-0.0649}
1.65-1.75
1.6 {0.063}
{0.0650-0.0688}
1.75-1.85
1.7 {0.067}
{0.0689-0.0728}
1.85-1.95
1.8 {0.071}
{0.0729-0.0767}
1.95-2.05
1.9 {0.075}
{0.0768-0.0807}
2.05-2.15
2.0 {0.079}
{0.0808-0.0846}
2.15-2.25
2.1 {0.083}
{0.0847-0.0885}
2.25-2.35
2.2 {0.087}
{0.0886-0.0925}
2.35-2.45
2.3 {0.090}
{0.0926-0.0964}
2.45-2.55
2.4 {0.094}
{0.0965-0.1003}
2.55-2.65
2.5 {0.098}
{0.1 004-0.1 043}
2.65-2.75
2.6 {0.102}
{0.1 044-0.1 082}
2.75-2.85
2.7 {0.106}
{0.1083-0.1122}
2.85-2.95
2.8 {0.110}
{0.1123-0.1161}
2.95-3.05
2.9 {0.114}
{0.1162-0.1200}
3.05-3.15
3.0 {0.118}
{0.1201-0.1240}
Countershaft front bearing shim selective chart

Dimension F (mm {in}) Shim thickness (mm {in})
3.15-3.25
3.0 {0.118}
{0.1240-0.1279}
3.25-3.35
3.1 {0.122}
{0.1280-0.1318}
3.35-3.45
3.2 {0.126}
{0.1319-0.1358}
3.45-3.55
3.3 {0.130}
{0.1359-0.1397}
3.55-3.65
3.4 {0.134}
{0.1398-0.1437}
3.65-3.75
·3.5 {0.138}
{0.1438-0.1476}
3.75-3.85
3.6 {0.142}
{0.1477-0.1515}
3.85-3.95
3.7 {0.147}
{0.1516-0.1555}
05-508-2
TECHNICAL DATA [S15M-D, S15MX-D]
5th/Reverse clutch hub thrust washer
Thickness (mm {in})
3.00 {0.11B}
3.05 {0.120}
3.10 {0.122}
3.15 {0.124}
3.20 {0.126}
3.25 {0.12B}
3.30 {0.130}
3.35 {0.132}
3.40 {0.134}
Reverse gear thrust washer

Dimension C (mm {in}) Thickness (mm {in})
7.60-7.70
7.35 {0.2B9}
{0.300-0.303}
7.70-7.BO
7.45 {0.293}
{0.304-0.307}
7.BO-7.90
7.55 {0.297}
{0.30B-0.311}
7.90-8.00
7.65 {0.301}
{0.312-0.314}
8.00-B.10
7.75 {0.305}
{0.315-0.31B}
Reverse idler gear retaining ring

Thickness (mm {in})
1.5 {0.059}
1.6 {0.063}
1.7 {0.067}
1.B {0.071}
1.9{0.075}
05-508-3
SERVICE TOOLS [5R55S]
05-60 SERVICE TOOLS [5R55S]

(e SERVICE TOOLS[5R55S] ............ 05-60-1
SERVICE TOOLS[5R55S]
id0560h 1500400
100-001 303-0026 307-003
Slide Hammer Depth Holding Fixture,

Micrometer Transmission
307-015 307-049 307-050
Compressor, Protector, Piston Installer, Shift ~

Clutch Spring Seal Shaft Fluid Seal ~
307-051 307-091 307-309
Protector, Piston Handle, Torque @) )) Remover,

Seal Converter Torque
@) )) Converter Fluid
Seal
307-334 307-336 307-338
Aligner, Valve Sizer, Piston Sizer, Piston

Body (2 Seal Seal
required)
307-34& 307-349 307-351
Retainer, Torque Installer, Torque Alignment

Converter Converter Fluid Gauge, TR
Seal Sensor
308-375 307-397 307-398
Remover, Input Remover, Alignment Pins,

Shaft Oil Seal Transmission Transmission
Fluid Pump Pump
307-399 307-400 307-401
~t
Alignment Pins, Gauge Bar Compressor,
Transmission Cushion Spring
Pump
307-402 307-431 307-432 v-.;::
Q Compressor,
~'0
e 0 e e Aligner, Fluid Aligner, Fluid
Pump Pilot
C
Servo Cover Pump Handle
~
05-60-1
SERVICE TOOLS [SRSSS]
307-433-01 307-434 307-435
b1h] ~
307-433-02
..
Bonded Piston Installer,
307-433-03
.
'0 • • '0' •
• • 0\ • • .... \ •
Seal Sizer Transmission
Transmission
•
.'...
'0'
...~ .
••0 .
Extension
Test Plate and · . . . .. Housing Fluid
Gasket Seal
307-451/1 307-451/2 307-451/3
~
Transmission Transmission Transmission
Fluid Pump Seal
Aligner QD Fluid Pump Seal
Sizer
(I -j Fluid Pump Seal
Installer
307-S022 307-S039 308-002
Adjustment Set, Alignment Set, Installer,
~
Transmission Fluid Pump Transmission
Band Extension
Housing Oil
Seal
05-60-2
SERVICE TOOLS [S15M-D, S15MX-D]
05-608 SERVICE TOOLS [S1SM-D, S1SMX-D]

~ SERVICE TOOLS [S15M-D, S15MX-D] . 05-608-1
SERVICE TOOLS [S15M-D, S15MX-D]

DCF056000000W04
1: Mazda SST number
Example
1 :49 UN01 011
2:308-168
Socket
1 :49 0839 425C 1 :49 H027 002 1:49 G033 106

2:- 2:- 2:-
Bearing Puller Remover, Attachment

Set Bearing
1 :49 G033 102 1:49 H017101 1 :490813235

2:- 2:- 2:-
Handle ~ Hook Main Bearing

Puller & Installer
.~
1:49 0710 520 1:49 H025 003A 1 :49 G028 203

2:- 2:- 2:-
Bearing Puller Bearing Installer Support
1:49 F401 331 1:49 B034 201 1 :49 G030 338

2:- 2:- 2:-
Body Support Block Attachment E
1:49 B032 308 1 :490221 251A 1 :49 D032 326A

2:- 2:- 2:-
Attachment A Valve Guide Attachment A

Installer
05-608-1
SERVICE TOOLS [S1SM-D, S1SMX-D]
1:49 F401 337A 1:49 UN01 011 1 :49 0636 040
(j
2:- 2:308-168 2:-
~
Attachment C Socket Piston Pin
Installer ~
1 :49 G030 797 1 :49 F017 1AO 1:49 G030 728

2:- 2:- 2:-
Handle Wrench
@ Attachment 8
~
1 :49 H025 001 498012004
2:-
Valve seal
Installer pusher
e I
05-608-2
211-04-24 A Steering Column 211-04-24 A
PROCEDURE FOR INSERTING KEY BARREL INTO REPLACEMENT

STEERING COLUMN·
Models:
2002-05 Model Year Focus (excluding 8T170)
Summary:
The procedure outlined below should be followed to ensure the Focus steering
column is not inadvertently locked when installing the key barrel into the steering
column.
Information:
2002-05 Model Year Focus (excluding 8T170) steering columns can inadvertently be
permanently locked if the correct procedure for installing the key barrel is not
followed.
Note: If the steering column is locked with the white spacer removed and no key
barrel inserted, the column will be permanently locked. The column will then need
to be scrapped.
Follow the procedure below to ensure the column does not become locked:
1. Confirm the ignition switch spindle is in the "accessories" position

(as per Figure 1). When the ignition switch spindle is the accessories position the
column is able to be turned freely.
If the ignition switch spindle is in the "locked" position (as per Figure 2), depress the
spindle and turn the spindle clockwise to the "accessories" position. Do not remove
the white spacer when the spindle is in the "locked" position as the anti-theft locking
mechanism will be triggered and the column will be permanently locked.
G17608 en 02/2002.50 Focus

211·04·24 A Steering Column 211·04·24 A
Figure 1: Ignition switch spindle is in the "accessories" position
Figure 2: Ignition switch spindle is in the "locked" position - DO NOT remove white
spacer whilst spindle is in "locked" position
2. With the spindle in the "accessories" postion, carefully rotate the white plastic
spacer in the clockwise direction. Whilst rotating the white plastic spacer, watch the
ignition switch spindle and ensure that the spindle is not rotated out of the
"accessories" position. Rotate the white plastic spacer until it hits the stop position,
as per Figure 3.
G17608 en 02/2002.50 Focus

211-04-24 A Steering Column 211-04-24 A':~
Figure 3: White spacer has been rotated clockwise until stop position. Spindle is
now in correct position to be pulled out from steering column key barrel slot.
3. Carefully pull the white plastic spacer out from key barrel slot.
4. Confirm that the key barrel to be inserted into the column is in the "accessories"
position. Carefully insert key barrel into the key barrel slot in the steering column.
5. When the key barrel is correctly inserted the locking pin in the key barrel will pop
into the hole provided in the steering column lock assembly.
6. Confirm that column is able to be turned freely after inserting the key barrel.
G17608 en 02/2002.50 Focus

,
"
GENERAL INFORMATION

VEHICLE IDENTIFICATION NUMBER VEHICLE LIFT (2 SUPPORTS) AND
(VIN) CODE . ..................... 00-00-1 SAFETY STAND (RIGID RACK)
VEHICLE IDENTIFICATION NUMBERS POSITION . ...................... . 00-00-26
(VIN) . ........................... 00-00-1 TOWING ......................... . 00-00-27
HOW TO USE THIS MANUAL. ........ 00-00-2 IDENTIFICATION NUMBER
UNITS ........................... 00-00-11 LOCATIONS . .................... . 00-00-29
SERVICE CAUTIONS ............... 00-00-12 NEW STANDARDS . ................ . 00-00-30
INSTALLATION OF RADIO SYSTEM ... 00-00-18 ABBREVIATIONS . ................. . 00-00-32
ELECTRICAL SySTEM .............. 00-00-19 PRE-DELIVERY INSPECTION . ....... . 00-00-33
JACKING POSiTIONS ............... 00-00-25 SCHEDULED MAINTENANCE ....... . 00-00-34

dcfOOOOOOOOOw16
MNBBS1 D1 060123456
=====I==l I~
_ ___
Serial No. _
'--_ _ _ _ _ _ _ _P_a_nt_ _ W=A. A. Thailand

Model Yesr 7= 2007, 8=2008, 9=2009 .. .
Production year 6= 2006, 7=2007, 8=2008 .. .
Check Digit 0 to 9, X
Plant W= A. A. Thailand
L -_ _ _ _ _ _ _ _~N~o~m~e~a~nin~g~ 0
1=WL-C (2.5 L-DI)
Engine type 9= WE-C (3.0 L-DI)
'-------------~--
D= 2268-2721 kg {5001-6000 Ibs}
L -_ _ _ _..:::;G.:...:ro..::.;ss::....;v:...:.e~hic=le=_w:..:..;e:..:..;ig~h..:..t_ _ _ _ _ E= 2722-3175 kg {6001-7000 Ibs}
B= Regular cab.-with box
F= Double cab.-with box
1= Stretch cab.
2= Stretch cab.
Body style (with Rear Access System) -with box
M=Thaiiand
'--_ _ _ _ _ _ _ _ _ _ _ _P_r_od_u_ct_s_or_ce_ S= Japan
D= with Air bag (Driver side)
Air bag U= with Air bag (Driver, Passenger and Side air bag)
L -_ _ _ _ _ _ _ _ _..:...:W..:..;or.;..:ld;...;.;m""a;;.;.nu:;.;.fa:;.:c..:;;tu;.;...:re:..;..r.;.:;id..:..;en.;.:;ti.;.:.:fic:..:.;at.:;.:io..;.;,n_ MNA=FORD (Australian)
arnffw00001644
VEHICLE IDENTIFICATION NUMBERS (VIN)

MNA 8S······
MNA OS······
MNA LS······
MNA US······
arnffw00001612
00-00-1
GENERAL INFORMATION
HOW TO USE THIS MANUAL
dcfOOOOOOOOOw18
Range of Topics
• This manual contains procedures for performing all required service operations. The procedures are divided
into the following five basic operations:
Removal/Installation
Disassembly/Assembly
Replacement
Inspection
Adjustment
• Simple operations which can be performed easily just by looking at the vehicle (i.e., removal/installation of
parts, jacking, vehicle lifting, cleaning of parts, and visual inspection) have been omitted.
Service Procedure
Inspection, adjustment
• Inspection and adjustment procedures are
divided into steps. Important points regarding the SHOWS PROCEDURE ORDER
location and contents of the procedures are FOR SE VICE
explained in detail and shown in the illustrations.
SHOWS TIGHTENING
TORQUE
E1E9~ SPECIFICATIONS
Connect the gauge set from under
the vehicle to prevent contact with
the drive belt and the cooling fan.
WGIWXX0009E
00-00-2
GENERAL INFORMATION
Repair procedure
1. Most repair operations begin with an overview illustration. It identifies the components, shows how the parts fit
together, and describes visual part inspection. However, only removal/installation procedures that need to be
m.
performed methodically have written instructions.
2. Expendable parts, tightening torques, and symbols for oil, grease, and sealant are shown in the overview
illustration. In addition, symbols indicating parts requiring the use of special service tools or equivalent are also
shown.
3. Procedure steps are numbered and the part that is the main point of that procedure is shown in the illustration
with the corresponding number. Occasionally, there are important points or additional information concerning a
procedure. Refer to this information when servicing the related part.
SHOWS SERVICE
Procedure ITEM (S)
.~~~~~~~~~~~~
LOWER TRAILING LINK UPPER TRAILING LINK REMOVAUINSTALLATION
INDICATES RELEVANT
REFERENCES THAT NEED
" ." 1. Jack up the rear of the vehicle and support it with safety stands.
U
Removaillnstallation 2. Remove the undercover. (See 01-10-4 Undercover Removal
TO BE FOLLOWED DURING
Portion 3. Remove in the order indicated in the table. INSTALLATION
--------------------,-r,2
-- 4. Install in the reverse order of removal.
5. Inspect the rear wheel alignment and adjust it If necessary.
"Inspection After
Installation" Portion 1 ~G---(j
SHOWS PROCEDURE ORDER
FOR SERVICE
INSTALL THE PARTS BY ~'J.v-'"",

PERFORMING STEPS
1-31N REVERSE ORDER
SHOWS TIGHTENING
TORQUE
SPECIFICATIONS
SHOWS DETAILS
94-116 {9.5-11.9, 69-86}

SHOWS TIGHTENING
CD iii TORQUE UNITS
SHOWS REFERRAL
NOTES FOR SERVICE
1 Split pin 7 Slit in
"-2 Nut 6 Nut
ower tral In In a I Jomt 9 Upper trailing link ball joint
(See 02·14-5 Lower Trailing Link Ball Joint Removal Note) (See 02~14·5 Upper Trailing Link Ball Joint Removal Note)
Bolt 10 Nut
5 Lower trailing link 11 Upper trailing link
6 Dust boot (tower trailing link) 12 Dust boot (upper trailing link)
LowerTraliing Link Ball Joint, Upper Trailing Link UPPER TRAILING LINK
Ball Joint Removal Note
• Remove the ball joint using the SSTs.
SHOWS SPECIAL
SERVICE TOOL (SST)
NO.
/
SHOWS REFERRAL
NOTES FOR
SERVICE
DHUOOOZW5002
00-00-3
GENERAL INFORMATION
Symbols
• There are eight symbols indicating oil, grease, fluids, sealant, and the use of SST or equivalent. These symbols
show application points or use of these materials during service.
Symbol Meaning Kind
-,.....- New appropriate
I Apply oil engine oil or gear

oil
II
New appropriate
Apply brake fluid
brake fluid
•
New appropriate
Apply automatic
automatic
transaxlei
transaxlei
transmission fluid
transmission fluid
-A Appropriate
I Apply grease
grease
Appropriate
1r.m:l!iQ1 Apply sealant
sealant
Apply petroleum Appropriate

@ jelly petroleum jelly
O-ring, gasket,
iii Replace part
etc.
ED Use SST or
equivalent
Appropriate tools
Advisory Messages
• You will find several Warnings, Cautions, Notes, Specifications and Upper and Lower Limits in this
manual.
Warning
• A Warning indicates a situation in which serious injury or death could result if the warning is ignored.
Caution
• A Caution indicates a situation in which damage to the vehicle or parts could result if the caution is ignored.
Note
• A Note provides added information that will help you to complete a particular procedure.
Specification
• The values indicate the allowable range when performing inspections or adjustments.
Upper and lower limits

• The values indicate the upper and lower limits that must not be exceeded when performing inspections or
adjustments.
00-00-4
GENERAL INFORMATION
Troubleshooting Procedure
Basic flow of troubleshooting _
~-----------------------------~
CUSTOMER ARRIVES
I
WARNING LIGHT' NO WARNING LlGHT*
ON/FLASHING WITH SYMPTOM
CHECK FOR • CHECK DTC

PRIORITIZED DTC • IGNITION ON TEST, IDLING
TEST
DTC
•
WITHOUTDTC
DIAGNOSE BY DTC
(ON-BOARD DIAGNOSTIC) DIAGNOSE BY SYMPTOM
• DTCTABLE (SYMPTOM TROUBLESHOOTING)
• DTC 1. DIAGNOSTIC INDEX
TROUBLESHOOTING 2. QUICK DIAGNOSIS CHART
FLOW (IF MENTIONED)
3. SYMPTOM
*: INDICATOR LIGHTS AND WARNING TROUBLESHOOTING
LIGHTS THAT INDICATE MALFUNCTIONS
WGIWXX0001E
DTC troubleshooting flow (on-board diagnostic)

• Diagnostic trouble codes (DTCs) are important hints for repairing malfunctions that are difficult to simulate.
Perform the specific DTC diagnostic inspection to quickly and accurately diagnose the malfunction.
• The on-board diagnostic function is used during inspection. When a DTC is shown specifying the cause of a
malfunction, continue the diagnostic inspection according to the items indicated by the on-board diagnostic
function.
Diagnostic index
• The diagnostic index lists the symptoms of specific malfunctions. Select the symptoms related or most closely
relating to the malfunction.
Quick diagnosis chart (If mentioned)

• The quick diagnosis chart lists diagnosis and inspection procedures to be performed specifically relating to the
cause of the malfunction.
Symptom troubleshooting
• Symptom troubleshooting quickly determines the location of the malfunction according to symptom type.
00-00-5
GENERAL INFORMATION
Procedures for Use
Using the basic inspection (section 05)
• Perform the basic inspection procedure before symptom troubleshooting.
• Perform each step in the order shown.
• The reference column lists the location of the detailed procedure for each basic inspection.
• Although inspections and adjustments are performed according to the reference column procedures, if the
CFlIJSe of the malfunction is discovered during basic inspection, continue the procedures as indicated in the
action column.
SHOWS INSPECTION SHOW POINTS REQUIRING

SHOWS ITEM NAMES FOR
ORD ER ATTENTION BASED ON
DETAILED PROCEDURES
INSPECTION R ESULTS
BAS C INSPECTION
S EP INSPECTION ACTION /
/
1 Perform the mechanical system test. Yes Go to the next step. r
(See 05-13-3 MECHANICAL SYSTEM TEST.) No Repair or replace any malfunctioning parts according to
Is mechanical system normal? the inspection result.
2 Turn the ignition switch to the ON position. Yes Go to next step.
When the seleelor lever is moved, does the seleelor No Inspect the selector lever and TR switch Rereir or
illumination indicate synchronized position to the replace malfunctioning parts.
lever location? Also, when other ranges are selected (flep. Ofi-14-fi flELECTOR LEVER INSPECTION.)
Irom N or P during Idling, does the vehicle move (See 05-13-10 TRANSMISSION RANGE (TR) SWITCH
within 1-2 s? INSPECTION.)
If the selector lever and TR switch are normal, go to the
next step.
3 Inspect the ATF color condition. Yes Go to the next step.

(See 05-13-8 AUTOMATIC TRANSMISSION No Repair or replace any malfunctioning parts according to
FLUID (ATF) INSPECTION.) the inspAr.tinn rARlllt.
Are ATF color and odor normal? Flush ATX and cooler line as necessary.
4 Perform the line pressure test. Yes Go to the next step.
(See 05-13-3 Line Pressure Test.) No Repair or replace any malfunctioning parts according to
Is the line pressure normal? the inspection result.
5 Perform the stall test. Yes Go to the next step.

(See 05-13-4 Stall Speed Test.)
REFERENCE Is the stall speed normal?
No Repair or replace any malfunctioning parts according to
the inspection result.
COLUMN
Yes Go to the next steo.
Inspect the voltage at the following TCM terminals.
(See 05-13-29TCM INSPECTION.) No Repair or replace any malfunctioning parts according to
the inspection result.
• Terminal 2J (TFT sensor)
• Terminals 1 D, 2B. 2C, 2E (TR switch)
• Terminal 2G (turbine sensor)
• Terminal2D (down switch)
• Terminal 21 (up switch)
• Terminal 1E (M range switch)
• Terminal 1W (steering shift switch)
Is the voltage normal?
DDAOOOZW4030
00-00-6
GENERAL INFORMATION
Using the DTC troubleshooting flow
• DTC troubleshooting flow shows diagnostic procedures, inspection methods, and proper action to take for each ~
DTC. Ii6iiI
DETECTION CONDITION
describes the condition
TROUBLE CONDITION under which the DTC is
detected.
DTC P0103
DTC P0103 MAF circuit high input
PCM monitors input voltage from TP sensor after ignition key is turned on. If input voltage at PCM terminal 68 is
above 8.25 V, PCM determines that TP circuit has malfunction.
Diagnostic support note

DETECTION
This is a continuous monitor (CeM).
CONDITION
MIL illuminates if PCM detects the above malfunction during first drive cycle. Therefore,
POSSIBLE PENDING CODE is not available.
CAUSE FREEZE FRAME DATE is available.
describes DTC is stored in the PCM memory.
MAF sensor malfunction
possible POSSIBl
Connector or terminal malfunction
CAUSE
point(s) of Open circuit in wiring between MAF sensor terminal 0 and PCM terminal 36 Indicates the
malfunction o en circuit in MAF sensor round circuit
FROM
circuit to be
MAIN RELAY
TERMINALD
PCM
inspected
(01 and 05
Indicates the section)
inspection step
No. to be
performed
(01 and 05
section)
MAFSENSOR PCM Indicates the
HARNESS SIDE CONNECTOR HARNESS SIDE CONNECTOR
connector
1P related to the
inspection
STEP shows
the order of ACTION
---=-
troubleshooting Diagnostic procedure describes the
STEP INSPECTION ACTION
appropriate
1 VERIFV FREEZE FRAME DATA HAS BEEN Ves Go to next step. i1'action to be taken
RECORDED No Record FREEZE FRAME DATA on repair order, then go /
Has FREEZE FRAME DATA been recorded? to next step. according to
2 VERIFV RELATED REPAIR INFORMATION Ves Pertorm repair or diagnosis according to available repair the result
AVAilABiliTY information.
Are related Service Bulletins and/or on~line
If vehicle is not repaired, then go to next step. (Yes/No) of the
reDair information available? No Go to next step. INSPECTION.
3 VERIFY CURRENT INPUT SIGNAL STATUS IS Ves Intermittent concern is existing. Go to INTERMITIENT
INSPECTION CONCERN INTERMITIENT OR CONSTANT CONCERNS TROUBLESHOOTING procedure.
(See 01-03-33 INTERMITIENT CONCERN _ Reference
describeS the Connect diagnostic tool to DLC~2.
method t 0 ,./ / Start engine.

Access MAF V PID using diagnostic tooi. No
TROUBLESHOOTING)
Go to next step.
item(s) to
perform
quickly Is MAF V PID within 0.2 - B.3 V?
ACTION.
4 INSPECT POOR CONNECTION OF MAF Repair or replace terminals, then go to Step 8.
determin e the SENSOR CONNECTOR
Ves
malfunct ioning Turn ignition key to OFF.

part(s). Disconnect MAF sensor connector.
Check for poor connection (damaged, pulled-
out terminals, corrosion etc.).
Are there any malfunctions?
DCFOOOZWB003
00-00-7
GENERAL INFORMATION
Using the diagnostic index
• Malfunction symptoms are listed in the diagnostic index under symptom troubleshooting.
• The exact malfunction symptoms can be selected by following the index.
No. TROUBLESHOOTING ITEM DESCRIPTION Page

(See 01-03-6 MELT NO_l MAIN OR
1 Melting of main or other fuses - OTHER FUSE)
2 MIL comes on MIL is illuminated incorrectly. (See 01-03-7 NO.2 MIL COMES ON)
3 Will not crank Starter does not work. (See 01-03-8 NO.3 WILL NOT CRANK)
Starter cranks engine at normal
Hard startilong crank/erratic starVerratic (See 01-03-9 NO.4 HARD START/
4 speed but engine requires excessive
crank LONG CRANK/ERRATIC CRANK)
cranking time before starting.
5 Engine stalls. I After start/at idle

Engine stops unexpectedly at idle
andlor after start.
(See 01-03-11 NO.5 ENGINE-STALLS
AFTER START/AT IDLE)
Starter cranks engine at normal (See 01-03-15 NO.6 CRANKS
6 Cranks normally but will not start
speed but engine will not run. NORMALLY BUT WILL NOT START)
Engine takes more time than normal (See 01-03-19 NO.7 SLOW RERUN
7 Slow return to idle
to return to idle speed. TO IDLE)
Engine speed fluctuates between
specified idle speed and lower (See 01-03-20 NO.8 ENGINE RUNS
8 Engine runs rough/rolling
speed and engine shakes ROUGH/ROLLING IDLE)
excessively.
Engine speed continues at fast idle
after warm-up. (See 01-03-23 NO.9 FAST IDLE/RUNS
9 Fast idle/runs on
Engine runs after ignition key is ON)
turned to OFF.
Engine stops unexpectedly at begin-
(See 01-03-24 NO.l0 LOW IDLE/
10 Low idle/stalls during deceleration ning of deceleration or recovery
STALLS DURING DECELERATION)
from deceleration.
BHEOOOOW102
00-00-8
m
GENERAL INFORMATION
Using the quick diagnosis chart
• The chart lists the relation between the symptom and the cause of the malfunction.
• The chart is effective in quickly narrowing down the relation between symptom and cause of the malfunction. It I I
also specifies a range of common causes when multiple malfunction symptoms occur.
• The appropriate diagnostic inspection relating to a malfunction cause as specified by the symptoms can be
selected by looking down the diagnostic inspection column of the chart.
PARTS WHICH MAY BE THE

CAUSE OF PROBLEMS
-------------~-------------
,-- ~
X: Applied
Possible factor
,;
<ii ~
<ii
~ ..:
"X
10 Q)
Q) <Ii .5 0.
Qi
Q)
0. III0 12 ~
0 ..: ~ 0. E Ii;
6 Q)
.5 Q)
~ s= Q)
.!a
e
f- 0. 0. 0.
PART WHICH MAYBE ~ s=

B .J:J 12 5" 12 ~ ~ 120.
" "
0. 0.
1;;
"" "' '1"3
.§ .5
THE SYMPTOM 0 ,; ~ .5 1;; '0' .5
s= :§ ~~ "
~
Q)
"'~ "0 ~
Q)
"
e" ·E'"" ~"
.!a .2
Q)
0
" ·iii"0
j 'i "0
1
Q)
a;Q)
-;nf :g
""' ~
E
1!!Q)
" E ~"
0 .,!!!
Cl J!!
t5 0-
"
g" s= " E~"' "0
.2' E ~ Ii;
" ,g" Qi" "E a" IJ "E ~ "
""U> 0.
"' "
0 Qi ,,0 0
§ 'iii"
Cl 0. Q)
.~ E E "
" ~ -g" ""'
~
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"
Cl "0 ,,~
·E" .5>
" '" "" .g" "ll '="" ~ " .5" ~
'6 6
Q) =Q)
~
,..
$
E 0
~ "8" "' 15 15 0 Q)
"s= E Q)
0
*
Q)
'iii E ,~
E-:'
EE ,..
1\ 0:2
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E .5 "'" "
Q) Q) Q)
" "' "6 1)0.

0
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U>
6 :s "
.5 .J:J Q)
'" E
-** "
Q) .~
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0 Cl 10 .9- 6 " Cl U>
~ f<
" "' "Ii;" ~Ii; j![5 ""Ii; Ii; .5>" i3.1;;" .,!!!Ii; "Ii;" ""
;::
0 12 $ " " ~6 .,!!!" 6~
"0 "0 Q)
E ·0 .5 " ~~ .,!!!
"0
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"0
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Cl <ii
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"0
60.
"
~ ~ .,!!!~ 12 3: s= 12 12 ~,.. 12 12 "i(l .;::~ 12 12 Ii;
.~
0. 0. 0. 0.
Q) "
0. 0. ~~ .5 .5
:a~ a
Cl Q)
:a"
Cl
C"
U" .§ .§ I
'2
815 u w" u ..:"*""
"0 Qi
Iii" 12
0. 0. 0. 0. 0. 0. 0. Cl
0 .§ .§ ~
0
u Ii:
0
.§ 0 .§ .§
...J
'"
(J)
"'" "'- rx
1 Melting of main or other fuses
2 MIL illuminates
3 Will not crank x x x x x x
4 Hard to start/long crank/erratic start/erratic x x
crank
5 Engine stalls. After start/at idle x x x
6 Cranks normally but will not start x x x
7 Slow return to idle x
8 Enaine runs rOlJgh/rollinQ idle x x x
9 Fast idle/runs on x x
10 Low idle/stalls durin deceleration x
11 EnQine stalls/auits. Acceleration/cruise x x x x
Engine runs rough. Acceleration/cruise x x x
Misses Acceleration/cruise x x x
Buck/jerk Acceleration/cruise! x x x
deceleration
Hesitation/stumble Acceleration x x x
Suraes Acceleration/cruise x x x
12 Lack/loss of power Acceleration/cruise x x x
CHOOSE THE 13 KnockinQ/pinQinQ Acceleration/cruise x x
ACTUALSYM PTOM 14 Poor fuel economy x x x x x
15 Emission comoliance x x x x
16 High oil consumption/leakage x x x
17 CoolinQ system concerns Overheating x x x x x
18 Coolina system concerns Runs cold x x
19 Exhaust smoke x x x
20 Fuel odor in engine compartment
21 EnQine noise x x x
22 Vibration concerns enQine x x x
23 NC does not work sufficient! .
24 NC is always on or Ale compressor runs
continuously.
25 NC is not cut off under WOT conditions. x
26 Exhaust sulfur smell x
27 Fuel refill concerns
28 Fuel fillinQ shut off issues
29 Constant voltaQe
30 Soark olua condition x
31 ATX concerns UpshitVdownshift
See Section 05-03A, TROUBLESHOOTING
enaaaement
BHEOOOOW105
00-00-9
GENERAL INFORMATION
Using the symptom troubleshooting
• Symptom troubleshooting shows diagnostic procedures, inspection methods, and proper action to be taken for
each trouble symptom.
DESCRIPTION
describes what
kind ofTROUBLE
SYMPTOM JROUBLE SYMPTOM
........
14~ Engine flares up or slips when upshifting or down shifting
........ When accelerator pedal is depressed for driveway, engine speed increase but vehicle speed increase
DESCRIPTION slowly.
• When accelerator is depressed while driving, engine speed increases but vehicle not.
• There is clutch slip because clutch is stuck or line pressure is low.
_ Clutch stuck, slippage (forward clutch, 3·4 clutch, 2-4 brake band, one-way clutch 1, one-way clutch 2)
• Line pressure low
POSSIBLE • Malfunction or mis-adjustment ofTP sensor
CAUSE • Malfunction of VSS
• Malfunction of input/turbine speed sensor
describes • Malfunction of sensor ground
possible • Malfunction of shift solenoid A, B or C
point of POSSIBLE
• Malfunction of TCC solenoid valve
• Malfunction of body ground
malfunction CAUSE
• Malfunction of throttle cable
• Malfunction of throttle valve body
- Poor operating of mechanical pressure
• Selector lever position disparity
• TR switch position disparity
Note
STEP shows
• Before following troubleshooting steps, make sure that Automatic Transaxle On-board Diagnostic and
the order of Automatic Transaxle Basic Inspection are conducted.
troubleshooting. ACTION
Diagnostic procedure describes the
STEP INSPECTION ACTION appropriate
1 • Is line pressure okay? Ves Go to next step. '- action to be
No Repair or replace any defective parts according to />'
Reference taken according
- -=--
inspection results.
item(s) for • Is shift point okay? Ves Go to next step to the result
additional _ (See 05-17-5 ROAD TESD No Go to symptom troubleshooting NO.9 "Abnormal shift". (Yes/No) of the
informatio n 3 • Stop engine and turn ignition switch on. Ves • Overhaul control valve body and repair or replace any INSPECTION .
defective parts.
-----
to perform • Connect diagnostic tool to DLC-2.
• Simulate SHIFT A, SHIFT B and SHIFT C PIDs (See ATX Workshop Manual GF4A-EL (1666-1A-99F)) --r-. How to
INSPECTIO N. forON.
• Is operating sound of shift solenoids heard? • If problem remains, replace or overhaul transaxle and
perform
repair or replace defective parts. ACTION is
N _ (See 05-17-15 AUTOMATIC TRANSAXLE
described in
INSPECTIO REMOVEVAUINSTALLATION)
describes th e the relative
method to material
quickly
No Inspect for bend, damage, corrosion or loose shown.
connection if shift solenoid A, B, or C terminal on ATX.
determine t he Inspect for shift solenoid mechanical stuck.
malfunction ing (See 05-17-14 Inspection of Operationr
If shift solenoids are okay, inspect for open or short Reference
partes). circuit between PCM connector terminal A, B or C. item(s) to
• Verify test results.
4 perform
- If okay, return to diagnostic index to service any additional symptoms.
- If malfunction remains, inspect related Service Bulletins and/or On-line Repair Information and perform repair or
ACTION.
diagnosis.
- If vehicle is repaired, troubleshooting completed.
- If vehicle is not repaired or additional diagnostic information is not available. replace or reprogram PCM.
DCFOOOZWB004
00-00-10
GENERAL INFORMATION
UNITS
Electric current A (ampere)

dcfOOOOOOOOOw19 m!I
Electric power W (watt)
Electric resistance ohm
Electric voltage V (volt)
mm (millimeter)
Length
in (inch)
kPa (kilo pascal)
Negative pressure mmHg (millimeters of mercury)
inHg (inches of mercury)
kPa (kilo pascal)
Positive pressure kgf/cm 2 (kilogram force per square

centimeter)
psi (pounds per square inch)
Number of
rpm (revolutions per minute)
revolutions
N·m (Newton meter)
kgf·m (kilogram force meter)
Torque kgf·cm (kilogram force centimeter)
ft·lbf (foot pound force)
in·lbf (inch pound force)
L (liter)
US qt (U.S. quart)
Imp qt (Imperial quart)
Volume ml (milliliter)
cc (cubic centimeter)
cu in (cubic inch)
fl oz (fluid ounce)
g (gram)
Weight
oz (ounce)

from these values.
Rounding Off

an upper limit, and rounded up if the 81 unit value is a lower limit. Therefore, converted values for the same 81
210-260 kPa {2.1-2.7 kgf/cm 2 , 30-38 psi}

270-310 kPa {2.7-3.2 kgflcm 2 , 39-45 psi}
00-00-11
GENERAL INFORMATION
SERVICE CAUTIONS
dcfOOOOOOOOOw20
Protection of the Vehicle
• Always be sure to cover fenders, seats and floor
areas before starting work.
BHJ0014W001
Preparation of Tools and Measuring Equipment

• Be sure that all necessary tools and measuring
equipment are available before starting any work.
BHJ0014W002
Special Service Tools

• Use special service tools or the equivalent when
they are required.
WGIWXX0024E
Disconnection of the Negative Battery Cable

• When working with the negative battery cable disconnected, wait for 1 min or more to allow the back up power
supply of the SAS control module to deplete its stored power after the cable is disconnected.
• Disconnecting the battery cable will delete the memories of the clock, audio, and DTCs, etc. Therefore, it is
necessary to note down the information stored in those memories before disconnecting the cable.
• If the battery had been disconnected during vehicle maintenance or for other reasons, the window will not fully
close automatically. Initialize the power window system for the power window main switch.
00-00-12
GENERAL INFORMATION
Oil Leakage Inspection

• Use either of the following procedures to identify the type of oil that is leaking.
id000000800200
Injury/damage Prevention Precautions
• Depending on the vehicle, the cooling fan may operate suddenly even when the engine switch is turned off.
Therefore., keep hands and tools away from the cooling fan even if the cooling fan is not operating to prevent
injury to personnel or damage to the cooling fan. Always disconnect the negative battery cable when servicing
the cooling fan or parts near the cooling fan.
Malfunction Diagnosis System

• Use the current diagnostic tool for malfunction diagnosis.
00-00-12a
,
GENERAL INFORMATION
Using UV light (black light)
1. Remove any oil on the engine or transaxle/transmission.
Note
......
...
,
• Referring to the fluorescent dye instruction manual, mix the specified amount of dye into the engine oil or i,
ATF (or transaxle/transmission oil).
2. Pour the fluorescent dye into the engine oil or ATF (or transaxle/transmission oil).
3. Allow the engine to run for 30 min.
4. Inspect for dye leakage by irradiating with UV light (black light), and identify the type of oil that is leaking.
5. If no dye leakage is found, allow the engine to run for another 30 min. or drive the vehicle then reinspect.
6. Find where the oil is leaking from, then make necessary repairs.
Note
• To determine whether it is necessary to replace the oil after adding the fluorescent dye, refer to the
fluorescent dye instruction manual.
Not using UV light (black light)

1. Gather some of the leaking oil using an absorbent white tissue.
2. Take samples of engine oil and ATF (or transaxle/transmission oil), both from the dipstick, and place them next
to the leaked oil already on the tissue.
3. Compare the appearance and smell, and identify
the type of oil that is leaking.
4. Remove any oil on the engine or transaxlel
transmission. ~~,,~
5. Allow the engine to run for 30 min. ATFOR
TRANSAXLEI
~r~ ~
6. Check the area where the oil is leaking, then TRANSMISSION OIL ~ ENGINE OIL
make necessary repairs.
~/~1 ;;fi LEAKED OIL
CDAOOOZWA003
Removal of Parts
• While correcting a problem, also try to determine
its cause. Begin work only after first learning
which parts and sUb-components must be
removed and disassembled for replacement or
repair. After removing the part, plug all holes and
ports to prevent foreign material from entering.
BHJ0014W005
Disassembly
• If the disassembly procedure is complex,
requiring many parts to be disassembled, all parts
should be marked in a place that will not affect
their performance or external appearance, and
identified so that reassembly can be performed
easily and efficiently.
WGIWXX0027E
00-00-13
GENERAL INFORMATION
Inspection During Removal, Disassembly
-
• When removed, each part should be carefully
inspected for malfunction, deformation, damage
and other problems.
WGIWXX0028E
Arrangement of Parts
• All disassembled parts should be carefully
arranged for reassembly.
• Be sure to separate or otherwise identify the parts
to be replaced from those that will be reused.
WGIWXX0029E
Cleaning of Parts
• All parts to be reused should be carefully and
thoroughly cleaned in the appropriate method.
Warning
• Using compressed air can cause dirt and
other particles to fly out causing injury to
the eyes. Wear protective eye wear
whenever using compressed air.
C5UOOOOW001
Reassembly
• Standard values, such as torques and certain
adjustments, must be strictly observed in the
reassembly of all parts.
• If removed, these parts should be replaced with
new ones:
Oil seals
Gaskets
a-rings
Lock washers
Cotter pins
Nylon nuts
WGIWXX0031E
00-00-14
GENERAL INFORMATION
• Depending on location:
Sealant and gaskets, or both, should be
applied to specified locations. When sealant
is applied, parts should be installed before
sealant hardens to prevent leakage.
Oil should be applied to the moving
components of parts.
Specified oil or grease should be applied at
the prescribed locations (such as oil seals)
before reassembly.
CHU0014W006
Adjustment
• Use suitable gauges and testers when making
adjustments.
BHJ0014W012
Rubber Parts and Tubing

• Prevent gasoline or oil from getting on rubber
parts or tubing.
WGIWXX0034E
Hose Clamps
• When reinstalling, position the hose clamp in the
original location on the hose and squeeze the
clamp lightly with large pliers to ensure a good fit.
WGlWXX0035E
00-00-15
GENERAL INFORMATION
Torque Formulas
• When using a torque wrench-SST or equivalent
combination, the specified torque must be
recalculated due to the extra length that the SST.
~.I. or equivalent adds to the torque wrench.
Recalculate the torque by using the following
formulas. Choose the formula that applies to you.
Torque Unit Formula
N·m N·m x [U(L+A)]
kgf·m kgf·m x [U(L+A)]
kgf·cm kgf·cm x [U(L+A)] ~~----~L~------~I
ft·lbf ft·lbf x [U(L+A)]

WGIWXX0036E
in·lbf in·lbf x [U(L+A)]
A : The length of the SST past the torque wrench drive.

L : The length of the torque wrench.
Vise
• When using a vise, put protective plates in the
jaws of the vise to prevent damage to parts.
PROTECTIVE PLATES
CHU0014W010
Dynamometer
• When inspecting and servicing the power train on the dynamometer or speedometer tester, pay attention to the
following:
Place a fan, preferably a vehicle-speed proportional type, in front of the vehicle.
Make sure the vehicle is in a facility with an exhaust gas ventilation system.
Since the rear bumper might deform from the heat, cool the rear with a fan. (Surface of the bumper must be
below 70°C {158°F} degrees.)
Keep the area around the vehicle uncluttered so that heat does not build up.
Watch the water temperature gauge and do not overheat the engine.
Avoid added load to the engine and maintain normal driving conditions as much as possible.
Note
• When only the front or rear wheels are rotated on a chassis dynamometer or equivalent, the ABS CM
determines that there is a malfunction in the ABS and illuminates the following lights:
Vehicles with ABS
• ABS warning light
• Brake system warning light
• If the above lights are illuminated, dismount the vehicle from the chassis dynal1')ometer and turn the
ignition switch to the LOCK position. Then, turn the ignition switch back to the ON position, run the vehicle
at 10 km/h or more and verify that the warning lights go out. In this case, a DTC will be stored in the
memory. Clear the DTC from the memory by following the memory clearing procedure [ABS] in the on-
board diagnostic system. (See 04-02A-2 ON-BOARD DIAGNOSIS [REAR ABS].)(See 04-02B-2
ON-BOARD DIAGNOSIS [4W-ABS]
00-00-16
GENERAL INFORMATION
•
4WD inspection/service
Speedometer tester measurement
Caution ( .. ";
• Install the tension bar (chain wire) to the tie down hook and secure the vehicle to prevent it from
rolling and running off.
• Do not accelerate suddenly from a standstill or accelerate/decelerate rapidly.
Free roller type

1. Align the free rollers with the wheel base and tread, then set them on the floor properly.
2. Drive the vehicle slowly onto the tester roller and
free rollers.
3. Start the engine and accelerate gradually to
inspect the speedometer.
4. After inspection, decelerate gradually with gentle
braking.
Propeller shaft removal type
1. Remove the propeller shaft. (See 03-15-2
PROPELLER SHAFT REMOVAU
INSTALLATION.)
DBGOOOZWB022
2. Place the front wheels on the tester roller.

3. Accelerate gradually and inspect the
speedometer.
4. After inspection, decelerate gradually with gentle
braking.
5. Install the propeller shaft. (See 03-15-2
PROPELLER SHAFT REMOVAU
INSTALLATION.)
DBGOOOZWB023
Brake tester measurement

1. Place the wheels (front or rear) to be measured
on the tester roller.
2. Shift to the N position/neutral.
3. Activate the tester roller and measure braking
force.
If there is a large amount of brake drag force, the
electronic control system coupling may be
affected. Jack up all four wheels to eliminate the
effect of the coupling and rotate each wheel by
hand to verify the rotation condition.
DBGOOOZWB024
00-00-17
GENERAL INFORMATION
Wheel balancer (on the vehicle balancer)
1. Jack up all four wheels.
2. Support the wheels (front or rear) on the side to be measured (near the wheels) using a wheel balancer sensor
~ stand.
'3. Support the wheels on the side not to be
, measured (near the wheels) using safety stands.
4. Set up the wheel balancer and rotate the wheels
using engine drive to measure the wheel balance.
DBGOOOZWB025
SST
• Some global SST or equivalent are used as SSTs necessary for vehicle repair. Note that these SSTs are
marked with global SST numbers.
• Note that a global SST number is written together with a corresponding Mazda SST number as shown below.
Example (SERVICE TOOLS)
1: 49 UN303 009
2: 303-009
Crankshaft Damper Remover
1: Mazda SST number

B6EOOOZWC001
Example (Except SERVICE TOOLS)
303-009 -Global SST Number

(49 UN30 3009) -Mazda SST Number
B6EOOOZWC002
INSTALLATION OF RADIO SYSTEM

dcfOOOOOOOOOw21
• If a radio system is installed improperly or if a high-powered type system is used, the CIS and other systems
may be affected. When the vehicle is to be equipped with a radio, observe the following precautions:
Install the antenna at the farthest point from control modules.
Install the antenna feeder as far as possible from the control module wiring harnesses.
Ensure that the antenna and feeder are properly adjusted.
Do not install a high-powered radio system.
00-00-18
GENERAL INFORMATION
ELECTRICAL SYSTEM
dcfOOOOOOOOOW22B:
Electrical Parts
Battery cable
• Before disconnecting connectors or removing
electrical parts, disconnect the negative battery
cable.
Wiring Harness
• To remove the wiring harness from the clip in the
engine room, pry up the hook of the clip using a
flathead screwdriver.
WGIWXX0039E
Caution NO GOOD
• Do not remove the wiring harness
protective tape. Otherwise, the wires
could rub against the body, which could
result in water penetration and electrical
shorting.
CHUOOOOW010
Connectors
Disconnecting connectors
• When disconnecting a connector, grasp the
connectors. not the wires. GOOD NO GOOD
CHUOOOOW014
00-00-19
GENERAL INFORMATION
• Connectors can be disconnected by pressing or
pulling the lock lever as shown.
WGIWXX0042E
Locking connector
• When locking connectors, listen for a click
indicating they are securely locked.
WGIWXX0043E
Inspection
• ·When a tester is used to inspect for continuity or
measuring voltage, insert the tester probe from GOOD NO GOOD
the wiring harness side.
CHUOOOOW011
• Inspect the terminals of waterproof connectors

from the connector side since they cannot be GOOD NO GOOD
accessed from the wiring harness side.
Caution
• To prevent damage to the terminal, wrap
a thin wire around the tester probe before
inserting into terminal.
00-00-20
GENERAL INFORMATION
Terminals
~----------~BDI
Inspection
• Pull lightly on individual wires to verify that they
are secured in the terminal.
WGIWXX0064E
Replacement
• Use the appropriate tools to remove a terminal as
shown. When installing a terminal, be sure to
insert it until it locks securely.
• Insert a thin piece of metal from the terminal side
of the connector and with the terminal locking tab
pressed down, pull the terminal out from the
connector.
WGIWXX0046E
Sensors, Switches, and Relays

• Handle sensors, switches, and relays carefully.
Do not drop them or strike them against other NO GOOD
objects.
CHUOOOOW013
00-00-21
GENERAL INFORMATION
Wiring Harness
Wiring color codes
• Two-color wires are indicated by a two-color code
~I symbol.
i • The first letter indicates the base color of the wire
and the second is the color of the stripe.
BIR BRIY
CODE COLOR CODE COLOR

B Black 0 Orange
BR Brown P Pink
G Green R Red
GY Gray V Violet
L Blue W White
LB Light Blue Y Yellow
LG Light Green
WGIWXX0048E
Fuse
Replacement
• When replacing a fuse, be sure to replace it with
one of the same capacity. If a fuse malfunctions
again, the circuit probably has a short and the
wiring should be inspected.
• Be sure the negative battery terminal is
disconnected before replacing a main fuse.
DCF921ZWB005
• When replacing a pullout fuse, use the fuse puller.
PULLER
WGIWXX0050E
Viewing Orientation for Connectors

• The viewing orientation for connectors is indicated with a symbol.
• The figures showing the viewing orientation are the same as those used in Wiring Diagrams.
• The viewing orientations are shown in the following three ways.
00-00-22
GENERAL INFORMATION
•
Part-side connector
The viewing orientation for part-side connectors is
from the terminal side. _______ PART NAME'
* : Part names are shown only when there are I
PCM (.
multiple connector drawings.
~I: I~I
1111011111
1
I VIEWING
CONNECTO~ CORIENTATION
" SYMBOL
....
PART
VIEWING ORIENTATION
PART-SIDE CONNECTOR
DBGOOOZWB015
Vehicle harness-side connector

The viewing orientation for vehicle wiring harness- NAME OF CONNECTING
side connectors is from the wiring harness side. PART'
* : Part names are shown only when there are
multiple connector drawings. PCM
/
~ ~I n
1 1 1 1 1 1 1 1 1 {I
I
CONNECTOR
VIEWING
ORIENTATION
SYMBOL
VEHICLE WIRING
HARNESS-SIDE
CONNECTOR VIEWING ORIENTATION
VEHICLE WIRING HARNESS

DBGOOOZWB016
Other
When it is necessary to show the terminal side of the
vehicle wiring harness-side connectors, such as the
DLC-2
following connectors, the viewing orientation is from
the terminal side.
• Main fuse block and the main fuse block relays
• Data link connector
• Check connector
• Relay box
CONNECTOR
VIEWING
~~t ORIENTATION
/~____ SYMBOL
VEHICLE WIRING HARNESS VIEWING ORIENTATION
DBGOOOZWB017 _.
00-00-23
GENERAL INFORMATION
Electrical Troubleshooting Tools
Jumper wire
.,-..... Caution
I • Do not connect a jumper wire from the power source line to a body ground. This may cause
burning or other damage to wiring harnesses or electronic components.
• A jumper wire is used to create a temporary

circuit. Connect the jumper wire between the
terminals of a circuit to bypass a switch.
WGIWXX0067E
Voltmeter
• The DC voltmeter is used to measure circuit POWER SOURCE LINE
voltage. A voltmeter with a range of 15 V or more
is used by connecting the positive (+) probe (red
lead wire) to the point where voltage will be
measured and the negative (-) probe (black lead
wire) to a body ground.
Ohmmeter
Caution
• Do not connect the ohmmeter to any circuit where voltage is applied. This will damage the
ohmmeter.
• The ohmmeter is used to measure the resistance NO GOOD

between two points in a circuit and to inspect for
continuity and short circuits.
POWER SOURCE LINE
CHUOOOOW005
00-00-24
GENERAL INFORMATION
Precautions Before Welding
A vehicle has various electrical parts. To protect the parts from excessive current generated when welding, be s u r e .
to perform the following procedure. • •
1. Turn the ignition switch to the LOCK position. . . . _
2. Disconnect the battery cables.
3. Securely connect the welding machine ground

near the welding area.
4. Cover the peripheral parts of the welding area to
protect them from weld spatter.
JACKING POSITIONS
dcfOOOOOOOOOw23
Warning
• Lifting a vehicle that is not stabilized is dangerous. The vehicle can slip off the lift and cause
serious injury and/or vehicle damage. Make sure that the vehicle is on the lift horizontally by
adjusting the height of the support at the end of the arm of the lift.
• Use safety stands to support the vehicle after it has been lifted.
Front
• Near the center of the crossmember.
2WD
00-00-25
GENERAL INFORMATION
4WD
DBGOOOZWB007
Rear
• At the center of the rear differential.
VEHICLE LIFT (2 SUPPORTS) AND SAFETY STAND (RIGID RACK) POSITION

dcfOOOOOOOOOw24
Vehicle Lift Positions
Warning
• Unstably lifting a vehicle is dangerous. The vehicle can slip off the lift and cause serious injury
and/or vehicle damage. Make sure that the vehicle is on the lift horizontally by adjusting the height
of support at the end of the arm of the lift.
Front
DBGOOOZWB003
Rear
DBGOOOZWB004
00-00-26
GENERAL INFORMATION
Safety Stand Positions
Front
DBGOOOZWB009
Rear
TOWING
dcfOOOOOOOOOw25
• Proper lifting and towing are necessary to prevent damage to the vehicle.
Particularly when towing a 4WD vehicle, where all the wheels are connected to the drive train, proper
transporting of the vehicle is absolutely essential to avoid damaging the drive system. Government and local
laws must be followed.
• A towed vehicle usually should have its rear
~
wheels off the ground. If excessive damage or
other conditions prevent this, use wheel dollies.
~~ WHEEL DOLLIES
~ DBGOOOZWB018
Caution
• Do not tow with sling-type equipment.
This could damage the vehicle. Use
wheel-lift or flatbed equipment.
Caution
• Follow these instructions when towing
the vehicle with all wheels on the ground
or with the front wheels on the ground
and the rear wheels raised.
1. Shift to neutral.
2. Turn the ignition switch to the ACC
pOSition.
DBGOOOZWB019
3. Release the parking brake.
• Remember that power assist for the
brakes and steering will not be available when the engine is not running.
00-00-27
GENERAL INFORMATION
• If the transmission, 4WD system, rear axle, and steering system are not damaged, the vehicle may be towed
on all four wheels. If any of these components are damaged, use wheel dollies or flatbed equipment.
Caution
• Follow these instructions when towing the 4WD vehicle with all wheels on the ground or with the
front wheels on the ground and the rear wheels raised.
1. Put the transfer shift lever in 2H.
2. Set the remote free-wheel system to FREE mode.
• Remember that power assist for the brakes and steering will not be available when the engine is
not running.
• If towing service is not available in an emergency, the vehicle may be towed with all four wheels on the ground
using the towing hook at the front of the vehicle.
Only tow the vehicle on paved surfaces for short distances at low speeds.
TowinglTiedown Hooks
Caution
• The towing hook should be used in an emergency (to get the vehicle out of a ditch for example).
• When using the towing hooks, always pull the cable or chain in a straight direction with respect to
the hook. Apply no sideways force.
• Don't use the tiedown hooks under the front for towing. They are designed ONLY for tying down
the vehicle when it's for towing will damage the bumper.
Note
• When towing with chain or cable, wrap the chain or cable with a soft cloth near the bumper to prevent
damage to the bumper.
Towing Hooks
2WD (EXCEPT HI-RIDER)
DCFOOOZWB009
4WD (HI-RIDER)
TIEDOWN HOOKS
DCFOOOZWB006
00-00-28
GENERAL INFORMATION
Tiedown Hooks
Caution
• Do not use the hook loops under the
front for towing. They are designed ONLY
,---------------.D
2WD (EXCEPT HI-RIDER)
for tying down the vehicle when it is
being transported. Using them for towing
will damage the bumper.
DCFOOOZWB007
4WD (HI-RIDER)
DCFOOOZWB008
IDENTIFICATION NUMBER LOCATIONS

dcfOOOOOOOOOw26
Vehicle Identification Number (VIN)
nRGnnn7WRnn?
Engine Identification Number
DBGOOOZWB005
00-00-29
GENERAL INFORMATION
NEW STANDARDS
dcfOOOOOOOOOw27
Name Name
ation ation
APP Accelerator Pedal Position - Accelerator Pedal Position
B+ Battery Positive Voltage VB Battery Voltage
LOAD Calculated Load Voltage - -
CPP Clutch Pedal Position - Clutch Position
CIS Continuous Fuel Injection System EGI Electronic Gasoline Injection System
FSO
solenoid
lAC Idle Air Control - Idle Speed Control
- InputlTurbine Speed Sensor - Pulse Generator
MAF Mass Air Flow - Mass Air Flow
OBD On-Board Diagnostic - Diagnosis/Self Diagnosis
00-00-30
GENERAL INFORMATION

Name Name
ation ation
- Output· Speed Sensor - Vehicle Speed Sensor 1
PIO Parameter Identification - Parameter Identification
Pulsed
injection
RAM Random Access Memory - -
Injection
AIR Secondary Air Injection - Secondary Air Injection System with air
pump
- Shift Solenoid A
- Shift Solenoid B
- Shift Solenoid C - 3-4 Shift Solenoid Valve
TP Throttle Position - -
TCM
Module

- - ATF Thermosensor
Temperature Sensor
VAF sensor Volume Air Flow Sensor - Air Flow Sensor
WUTWC - Catalytic Converter #5
Converter
#1: Diagnostic trouble codes depend on the diagnostic test mode

#2: Controlled by the PCM
#3: In some models, there is a fuel pump relay that controls pump speed. That relay is now called the fuel pump
relay (speed).
#4: Device that controls engine and powertrain
#5: Directly connected to exhaust manifold
#6: Part name of diesel engine
00-00-31
GENERAL INFORMATION
ABBREVIATIONS
id0000001572a2
lABS Antilock Brake System OlD Overdrive

',AlC Air Conditioning OSS Output Shaft Speed
IAT Automatic Transmission PCM Powertrain Control Module
ATDC After Top Dead Center PCV Positive crankcase ventilation
ATF Automatic Transmission Fluid PDS Portable Diagnostic Software
BTDC Before Top Dead Center PID Parameter Identification
CAN Controller Area Network PRC Pressure regulator control
CM Control Module PIS Power Steering
ECT Engine Coolant Temperature P/w Power Window
ELR Emergency Locking Retractor RF Right Front
ESA Electronic spark advance RFW Remote Freewheel
EX Exhaust RH Right Hand
GND Ground RR Right Rear
HI High SAS Sophisticated Air Bag Sensor
HLA Hydraulic lash adjuster SST Special Service Tool
HU Hydraulic Unit SW Switch
IDS Integrated Diagnostic Software TDC Top Dead Center
IN Intake TFT Transmission Fluid Temperature
INT Interm ittent TNS Tail Number Side Lights
ISS Intermediate Shaft Speed TSS Turbine Shaft Speed
KOEO Key On Engine Off VBC Variable Boost Control
KOER Key On Engine Running VENT Ventilation
LCD Liquid Crystal Display VSC Variable Swirl Control
LED Light Emitting Diode WDS Worldwide Diagnostic System
LF Left Front W/M Workshop Manual
LH Left Hand 1GR First Gear
LO Low 2GR Second Gear
LR Left Rear 3GR Third Gear
LSD Limited Slip Differential 4GR Fourth Gear
LSPV Load Sensing Proportioning Valve 5GR Fifth Gear
M Motor 4W-ABS 4-Wheel Antilock Brake System
MAX Maximum 4x2 4-wheel 2-d rive
MIL Malfunction Indicator Lamp 4x4 4-wheel 4-drive
MIN Minimum
00-00-32
GENERAL INFORMATION
PRE-DELIVERY INSPECTION
dCfOOOOOOOOOW31,ID
Pre-Delivery Inspection Table
Exterior I,
INSPECT and ADJUST, if necessary, the following part to specification: J'
OGlass, exterior bright metal and paint for damage
OWheel lug nuts
OAII weatherstrips for damage or detachment
OOperation of bonnet release and lock
OOperation of fuel-filler lid
ODoor operation and alignment
OHeadlight aiming
TRUNK ROOM
OCheck spare tire and air pressure
INSTALL the following part:
OWheel caps (if equipped)
OMast antenna (if equipped)
Under bonnet-engine off

INSPECT and ADJUST, if necessary, the following part to, specification:
OFuel, engine coolant, and hydraulic lines, fittings, connections, and components for leaks
OEngine oil level
OPower steering fluid level (if equipped)
OBrake and clutch master cylinder fluid level
OWasher tank fluid level
ORadiator coolant level and specific gravity
OTightness of battery terminals
ODrive belt tensions
Interior
INSPECT the operations of the following part:
OSeat controls (slide and recline)
OSeat belts
OAir bag system using warning light
OCruise control system (if equipped)
OEngine switch and steering lock
OStarter interlock (if equipped)
OPower door lock (if equipped)
ODoor locks
OAII lights including warning, and indicator lights
OHorn, wipers, and washers
OWiper blades performance
OAudio system
OPower windows (if equipped)
ODefroster, and air conditioner at various mode selections (if equipped)
INSPECT the following part:
OPresence of spare fuse
OUpholstery and interior finish
INSPECT and ADJUST, if necessary, the following part:
OPedal height and free play of brake and clutch pedal
OParking brake
Under bonnet-engine running at operating temperature

INSPECT the following items:
Olgnition timing
On hoist
OUnderside fuel, engine coolant and hydraulic lines, fittings, connections, and components for leaks
OTires for cuts or bruises
OSteering linkage, suspension, exhaust system, and all underside hardware for looseness or damage
OManual transmission oil level
ODifferential oil level
OTransfer oil level
00-00-33
GENERAL INFORMATION
Road test
OBrake operation
~ OClutch operation
. .:WSteering control
OEngine general performance
OOperation of transfer
OEmergency locking retractors
OCruise control system (if equipped)
OOperation of meters and gauges, squeaks, rattles, and unusual noises
After road test

INSPECT for necessary owner information materials, tools, and spare tire in vehicle
The following part must be completed just before delivery to your customer.
OLoad test battery and charge if necessary (Load test result: Volts)
OAdjust tire pressure to specification
OClean outside of vehicle
Olnstall fuses for accessories
ORemove seat and cabin carpet protective covers
OVacuum inside of vehicle
Olnspect installation of option parts with invoice
SCHEDULED MAINTENANCE
Scheduled Maintenance Table for Australia.
Number of months or kilometers, whichever comes first
Months 6 12 18 24 30 36 42 48 54 60 66 72 78 84 90 96
Maintenance Interval
x1000 km 10 20 10 11 12 13 14 15 16
30 40 50 60 70 80 90
0 0 0 0 0 0 0
Engine valve clearance I I
Engine timing belt *1 Replace every 120,000 km
Engine timing belt auto tensioner Replace every 120,000 km
Engine oil *2 R R R R R R R R R R R R R R R R
Engine oil filter *2 R R R R R R R R R R R R R R R R
Drive belts *3 I I I I I I I I I I I I I I I I
Cooling system (Including coolant level
I I I I I I I I
adjustment)
Replace at first 200,000km or 10 years;
FL22 type *4
Engine coolant after that, every 100,000 km or 5 years
Others Replace at first 80,000 km or 4 years; after that, every 2 years
Air cleaner element *5 C C R C C R C C R C C R C C R C
Fuel filter R R R R R R R R
Fuel injection pump inlet filter C C C C C C C C
Fuel lines and hoses I I I I I I I I I I I I I I I I
Air intake system I I I I I I I I
Battery electrolyte level and specific gravity I I I I I I I I
Brake lines, hoses and connections I I I I I I I I
Brake fluid *6 I I I R I I I R I I I R I I I R
00-00-34
GENERAL INFORMATION
Parking brake I I I I I I I I I I I I I I I I
Power brake unit (Brake booster) and hoses I I I I I I I I
Disc brakes *7 I I I I I I I I I I I I I I I I
i
Drum brakes *7 I I I I I I I I
Power steering fluid, lines, hoses and
I I I I I I I I I I I I I I I I
connections
Steering operation and linkages *7 I I I I I I I I
Manual transmission oil *8 I I R I
Automatic transmission fluid *8 *9 Replace every 240,000 km
Rear differential oil (for 4x2) *8 R R R R
Front and rear differential oil (for 4x4) *8 R I R I R I R I
for Manual
I I R I
Transmission *8
Transfer oil (for 4x4)
for Automatic
Transmission *8 *9 Replace every 240,000 km
Driveshaft dust boots (for 4x4) I I I I
Front and rear propeller shaft joints (for 4x4) L L L L L L L L
Front and rear suspension and ball joints I I I I I I I I
Front wheel bearing grease (for 4x2 except
R R R R R R R R
Hi-Rider)
Wheel bearing lateral play (frqnt) and axial
I I I I I I I I
play (rear)
Exhaust system and heat shields Inspect every 80,000km
Bolts and nuts on chassis and body T T T T T T T T
Body condition (for rust, corrosion and
Inspect annually
perforation)
Tires (including spare tire)(with inflation
I I I I I I I I I I I I I I I I
pressure adjustment)
Tire rotation *9 Rotate every 10,000 km or 6 months
Road test I I I I I I I I I I I I I I I I
Diagnostic check of Vehicle Management and
I I I I I I I I
Safety Systems
Chart symbols
I: Inspect: Inspect and clean, repair, adjust, or replace if necessary.
R: Replace
C: Clean
L: Lubricate
T: Tighten
Remarks
• Emission control and related systems
The ignition and fuel systems are highly important to the emission control system and to efficient engine
operation.
All inspections and adjustments must be made by an expert repairer, we recommend an Authorized Ford
Repairer.
• After the prescribed period, continue to follow the described maintenance at the recommended intervals.
• Refer below for a description of items marked* in the maintenance chart.
*1: Replacement of the timing belt is required at every 120,000 km. Failure to replace the timing belt may result
in damage to the engine.
*2: If the vehicle is operated primarily under any of the following conditions, replace the engine oil and oil filter
more often than the recommended intervals.
a. Driving in dusty conditions
b. Extended periods of idling or low speed operation
c. Driving for long period in cold temperatures or driving regularly at short distance (less than 8 km) only
*3: Also inspect and adjust the power steering and air conditioner drive belts, if installed.
00-00-35
GENERAL INFORMATION
*4: Use FL22 type coolant in vehicles with the inscription "FL22" on the radiator cap itself or the surrounding
area. Use FL22 when replacing the coolant.
*5: If the vehicle is operated in very dusty or sandy areas, clean the air cleaner element at every 5,000 km or 3
months.
~'6: If the brakes are used extensively (for example, continuous hard driving or mountain driving) or if the vehicle
/ is operated in extremely humid climates, replace the brake fluid annually.
*7: If the vehicle is operated primarily under any of the following conditions, inspect the these items more often
than the recommended intervals.
a. Driving on bumpy roads, gravel roads, snowy roads or dirt roads
b. Driving uphill and downhill frequently
c. Repeated short-distance driving
*8: If this component(s) has been submerged in water, the oil should be replaced.
*9: If the vehicle is operated primarily under any of the following conditions, replace the fluid as follows.
- Automatic transmission: Every 50,000 km.
- Transfer case (attached to automatic transmission): Every 100,000 km.
a. Towing a trailer
b. Extension idling and/or low speed driving for long distances as in heavy commercial use such as
delivery, taxi, patrol car or livery
c. Operating in dusty conditions such as unpaved or dusty roads
d. Off-road operations
*10: If the vehicle is operated primarily under any of the following conditions, rotate the tires more often than the
recommended intervals.
a. Driving on bumpy roads, gravel roads, snowy roads or dirt roads
b. Driving uphill and downhill frequently
c. Repeated short-distance driving
00-00-36
GENERAL INFORMATION
Scheduled Maintenance Service (Specific Work Required)
• The specific work required for each maintenance item is listed in the following table. (Please refer to the section
applicable to the model serviced.)
Maintenance Item Specific Work Required
ENGINE
Engine valve clearance Inspect engine vale clearance.
Engine timing belt Replace engine timing belt.
Engine timing belt auto tensioner Replace engine timing belt auto tensioner.
Drive belts Inspect for wear, cracks, fraying and tension.
Engine oil Replace engine oil and inspect for leakage.
Engine oil filter Replace engine oil filter and inspect for leakage.
COOLING SYSTEM
Cooling system (Including coolant level Check engine coolant level and quality, and inspect for leakage.
adjustment)
Radiator cap Inspect radiator cap.
Engine coolant Replace engine coolant.
FUEL SYSTEM
Idle speed Check engine idle rpm.
Idle mixture Inspect the CO and HC concentrations (see W/M).
Choke system Check system operation.
Air cleaner element Inspect dirt, oil and damage.
Clean air cleaner element (by blowing air).
Replace air cleaner element.
Fuel filter Replace fuel filter.
Fuel injection pump inlet filter Clean fuel injection pump inlet filter.
Fuel lines and hoses Inspect for cracks, leakage and loose connection.
Fuel lines, hoses and connections
Fuel injection system Update to injection amount correction with current diagnostic tool (see W/M).
Fuel system (Drain water) Drain water in fuel system.
Diesel particulate filter Replace diesel particulate filter.
Fuel additive for diesel particulate filter Fill up fuel additive.
IGNITION SYSTEM
Initial ignition timing Check initial ignition timing.
Spark plugs Inspect for wear, damage, carbon, plug gap and high-tension lead condition.
Replace spark plugs.
Ignition cables condition/security Inspect for damage, condition and connection.
EMISSION CONTROL SYSTEM
Evaporative system Check system operation (see W/M), vapor lines, vacuum fitting hoses and
Evaporative emission control system connection.
Crankcase emission control system Check system operation (see W/M), PCV valve, blow-by lines, vacuum fitting
hoses and connection.
E.G.R system Check system operation (see W/M), vacuum fitting hoses and connection.
MZR-CD (RF turbo) engine: Update to MAF correction for E.G.R control with
current diagnostic tool (see W/M).
Air intake systom Update to MAF correction (see W/M).
Throttle positioner system Check the diaphragm and system operation, vacuum fitting hoses and connection.
Dash pot Check system operation.
ELECTRICAL SYSTEM
Battery electrolyte level and specific Check battery electrolyte level and specific gravity.
gravity
Battery condition Check battery for corroded or loose connections and cracks.
Battery Check battery for leakage and corrosion.
All electrical system Check function of lighting system, windshield wiper (including wiper blade
Lighting system and windshield wipers condition), washer and power windows.
and washer
Head light alignment Check head light alignment.
CHASSIS AND BODY
Brake and clutch pedals Check pedal height and free play.
Brake pedals
00-00-37
GENERAL INFORMATION
Brake fluid Check brake fluid level and for leakage.

Replace brake fluid.
Clutch fluid Check Clutch fluid level and for leakage.
Brake lines, hoses and connections Inspect for cracks, damage, chafing, corrosion, scars, swelling and fluid leakage.
Parking brake Check parking lever stroke.
Power brake unit and hoses Check vacuum lines, connections, and check valve for improper attachment, air
Power brake unit (Brake booster) and tightness, cracks chafing and deterioration.
hoses
Disc brakes Inspect caliper for correct operation and fluid leakage, brake pads for wear. Check
disc plate condition and thickness. Test for judder and noise.
Drum brakes Inspect brake drum for wear and scratches: brake lining for wear, peeling and
cracks; wheel cylinder for fluid leakage. Test for judder and noise.
Manual steering gear oil Check manual gear oil level.
Power steering fluid, lines, hoses and Check power steering fluid level and lines for improper attachment, leakage,
connections cracks, damage, loose connections, chafing and deterioration.
Power steering fluid and lines
Steering operation and gear housing Check that the steering wheel has the specified play. Be sure to check for
Steering linkages tie rod ends and arms changes, such as excessive play, hard steering or strange noises. Check gear
Steering operation and linkages housing and boots for looseness, damage and grease/gear oil leakage. Check ball
joint, dust cover and other components for looseness, wear, damage and grease
leakage.
Front and rear suspension and ball joints Inspect for grease leakage, crack, damage and looseness.
Front suspension ball joints Inspect for grease leakage, crack, damage, looseness and wheel bearing play/
Front and rear suspension, ball joints and noise.
wheel bearing axial play
Wheel bearing axial play Inspect for wheel bearing play/noise.
Manual transmission/transaxle oil Check manual transmission/transaxle oil level and for leakage.
Replace manual transmission/transaxle oil.
Automatic transmission/transaxle fluid Check automatic transmission/transaxle fluid level.
level
Automatic transmission/transaxle fluid Replace automatic transmission/transaxle fluid.
Front and rear differential oil Check front and rear differential oil level and inspect for leakage.
Front differential oil Replace front and rear differential oil.
Front axle oil
Rear differential oil
Rear axle oil
Transfer oil Check transfer oil level inspect for leakage.
Replace transfer oil
Front and rear wheel bearing grease Remove wheel bearing and replace wheel bearing grease.
Front wheel bearing grease
_ Wheel bearing axial play Inspect wheel bearing play and noise.
Wheel bearing axial play (rear) and lateral
play (front)
Propeller shaft joints Lubricate propeller shaft joints.
Front propeller shaft joints
Rear propeller shaft joints
Driveshaft dust boots Inspect for grease leakage, crack, damage and looseness.
Wheel nuts Tighten wheel nuts.
Bolts and nuts on chassis and body Tighten bolts and nuts fastening suspension components, members and seat
Bolts and nuts on seats frames.
Body condition (for rust, corrosion and Inspect body surface for paint damage, rust, corrosion and perforation.
perforation)
Exhaust system and heat shields Inspect for damage, corrosion, looseness of connections and gas leakage.
Exhaust pipe connections
Tire rotation Rotate tires.
Tires (Including spare tire)(with inflation Check air pressure and inspect tires for tread wear, damage, cracks; and wheels
pressure adjustment) for damage and corrosion.
Flat tire repair kit Check tire repair fluid expiration date.
Hinges and catches Lubricate hinges and catches of doors, trunk lid and hood.
Underside of vehicle Inspect underside of vehicle (floor pans, frames, fuel lines, around exhaust system
etc.) for damage and corrosion.
00-00-38
GENERAL INFORMATION
Road test Check brake operation/clutch operation/steering control/operation of meters and

gauges/squeaks, rattles, or unusual noises/engine general performance/
emergency locking retractors.
Diagnostic trouble code by current Check diagnostic trouble code with current diagnostic tool (see W/M).
diagnostic tool
Diagnostic check of Vehicle Management Check the items below with WDS (see W/M).
and Safety Systems (1) Retrieve All CMDTCs
(2) PCM function test (except diesel engine models)
(3) PCM InpuVOutput Data Monitor (except diesel engine models)
(4) Adviser Comment (except diesel engine models)
AIR CONDITIONER SYSTEM
Cabin air filter Replace cabin air filter.
00-00-39
ENGINE 01
SECTION
OUTLINE ................. 01-00 INTAKE-AIR SYSTEM

ON-BOARD DIAGNOSTIC [WL-C, WE-C] ............. 01-13B
[WL-3] . . . . . . . . . . . . . . . . .. 01-02A FUEL SYSTEM [WL-3] ....... 01-14A
ON-BOARD DIAGNOSTIC FUEL SYSTEM
[WL-C, WE-C] . . . . . . . . . . . . 01-02B [WL-C, WE-C] ............. 01-14B
SYMPTOM EXHAUST SYSTEM [WL-3] ... 01-15A
TROUBLESHOOTING EXHAUST SYSTEM
[WL-3] . . . . . . . . . . . . . . . . . . 01-03A [WL-C, WE-C] ............. 01-15B
SYMPTOM EMISSION SYSTEM [WL-3] ... 01-1SA
TROUBLESHOOTING EMISSION SYSTEM
[WL-C, WE-C] . . . . . . . . . . .. 01-03B [WL-C, WE-C] ............. 01-1S.B
MECHANICAL [WL-3] ....... 01-10A CHARGING SYSTEM ........ 01-17
MECHANICAL STARTING SYSTEM ......... 01-19
[WL-C, WE-C] . . . . . . . . . . . . 01-10B CONTROL SYSTEM [WL-3] ... 01-40A
LU BRICATION [WL-3]. . . . . .. 01-11 A CONTROL SYSTEM
LUBRICATION [WL-C, WE-C] ............. 01-40B
[WL-C, WE-C] . . . . . . . . . . .. 01-11 B TECHNICAL DATA [WL-3] .... 01-50A
COOLING SYSTEM [WL-3] ... 01-12A TECHNICAL DATA
COOLING SYSTEM [WL-C, WE-C] ............. 01-50B
[WL-C, WE-C] . . . . . . . . . . . . 01-12B SERVICE TOOLS [WL-3] ..... 01-S0A
INTAKE-AIR SYSTEM SERVICE TOOLS
I
[WL-3] . . . . . . . . . . . . . . . . .. 01-13A [WL-C, WE-C] ............. 01-S0B
\.
01-00 OUTLINE
ENGINE TECHNICAL DATA [WL-3] ...• 01-00-1
ENGINE TECHNICAL DATA [WL-3]

dcf01000000Ow01
Drive Belt Deflection
(mm {in})
Drive Belt New* Used Limit
7.4-9.4 8.7-10.4
Generator 14.3 {0.56} or more
{0.30-D.37} {0.35-0.40}
6.1-6.9 7.1-8.0
a 11.3{0.44} or more
{0.24-D.27} {0.28-0.31}
Ale
10.0-11.0 11.3-12.6
b 17.4 {0.69} or more
{0.40-D.43} {0.45-0.49}
01-00-1
OUTLINE
Drive Belt Tension
Drive Belt New

. Used Limit
(N {kgf, Ibf})
490-637 431-539
Generator 225 {22.9, 50.6} or less
{50.0-64.9, 111-143} {44.0-54.9,96.9-121}
455-572 353-431
AlC 156 {15.9, 35.1} or less
{46A-58.3,103-128} {36.0-43.9, 79A-96.8}
Item Specification
IN: 0.05 - 0.15 mm {0.0020 - 0.0059 in}
EX: 0.15 -0.25 mm {0.0060 - 0.0098 in}
Standard: 2,942 {30, 427} [200]
Compression (kPa {kgf/cm 2 , psi} [rpm]) Minimum: 2,648 {27, 384} [200]
Standard tensioner spring length 63.0 mm {2A8 in}
Bolt head mark W
Bolt head mark N
Standard length: 113.2-113.8 mm {4A57-4A80 in}
Front oil seal press-in amount 0.0-0040 mm {0.0-0.015 in}
Fuel injection pump plunger adjustment value 0.95-1.05 mm {0.038-0.041 in}
Oil pressure [2,500 rpm] 410-570 kPa {4.19-5.81 kgf/cm 2 , 59.6-82.6 psi}

Item Specification
Grade API CO, CE or CF-4
Viscosity (SAE) 5W-30,10W-30
Item Specification
Oil replacement: 5.5 {5.8 US qt, 4.8 Imp qt}
Oil capacity (approx. quantity) Oil and oil filter replacement: 6.2 {6.6 US qt, 5.5 Imp qt}
Total (dry engine): 6.7 {7.1 US qt, 5.9 Imp qt}
Front oil seal press-in amount 0.0-0040 mm {0.0-0.015 in}
Fuel injection pump oil seal press-in amount 0.0-0040 mm {0.0-0.015 in}
Standard oil pump tip clearance 0.10-0.19 mm {0.0040-0.0074 in}
Engine coolant capacity (approx. quantity) 8.8 L {9.3 US qt, 7.7 Imp qt}
Cooling system cap valve opening pressure 93.2-122.6 kPa {0.95-1.25 kgf/cm 2 , 13.5-17.8 psi}
Initial-opening temperature and lift of the valve 80-84 °C {176-183 OF}
Full open temperature 95°C {203 OF}
Full open life 8.5 mm {0.33 in} or more
Battery electrolyte specific gravity [20°C {68 OF}] 1.22-1.29
65031R (56): 165 A
Battery load test current
95031 R (64): 250 A
Vehicles with immobilizer system: 5-25 mA
Battery back-up current
Vehicles without immobilizer system: 10 mA or less
65031 R (56): 4.0-5.0 A
Battery slow charge current
95031 R (64): 6.5-8.0 A
65031 R (56): 30 A
Battery quick charge current [30 min.]
95031 R (64): 40 A
Tightening torque: 12-25 N·m {123-254 kgf·cm, 107-221 in·lbf}
Terminal B: B+
Generator standard voltage [Engine switch ON] Terminal L: Approx. 1 V
Terminal S: B+
01-00-2
OUTLINE
Item Specification
Terminal B: 14.1-14.7 V
Generator standard voltage [Idle, 20°C {68 OF}] Terminal L: 13.0-14.0 V
Terminal S: 14.1-14.7 V
Generator generated current (reference value) [Conditions] Ambient temperature: 20°C {68 OF}, Voltage:
13.5 V, Engine hot
Engine speed (rpm) Terminal B current (Lower limit of current must be more than 0 A.)
1,000 Q-55A
2,000 Q-70A
Item Specification
Generator rotor resistance (between slip rings) [20°C
{68 OF}] 2.3-2.7 ohms
Standard: 18.5 mm {0.73 in}

Generator brush length
Minimum: 5.0 mm {0.2 in}
Standard: 4.8-6.0 N {0.49-0.61 kgf, 1.08-1.34 Ibf}
Generator brush spring force
Minimum: 2.16 N {0.22 kgf, 0.49 Ibf}
Starter no load test voltage 11 V
Starter no load test current 130 A or less
Starter pinion gap o mm {O in}
Starter armature runout 0.1 mm {0.039 in} max.
Standard: 32 mm {1.26 in}
Starter commutator diameter
Segment groove depth of starter commutator
Starter brush length
Minimum: 11 mm {0.43 in}
Standard: 26.7-36.1 N {2.73-3.68 kgf, 6.01-8.11Ibf}
Starter brush spring force
Minimum: 14.7 N {1.5 kgf, 3.3Ibf}
01-00-3
01-02B ON-BOARD DIAGNOSTIC [WL-C, WE-C]

ON-80ARD DIAGNOSTIC DTC P0380 [WL-C, WE-C] ...•.....•.. 01-028-86
WIRING DIAGRAM [WL-C, WE-C] ••• 01-028-2 DTC P0403 [WL-C, WE-C] ............ 01-028-89
FOREWORD [WL-C, WE-C] .•.•..•..• 01-028-6 DTC P0405 [WL-C, WE-C] •...••...•.. 01-028-91
PENDING TROU8LE CODES DTC P0406 [WL-C, WE-C] ...•....•••• 01-028-93
[WL~C, WE-C] .••....•.•..•..••..• 01-028-6 DTC P0489 [WL-C, WE-C] ...••...•... 01-028-95
FREEZE FRAME DATA [WL-C, WE-C] .• 01-028-6 DTC P0490 [WL-C, WE-C] ••..•....... 01-028-96
READ/CLEAR DIAGNOSTIC DTC P0500 [WL-C, WE-C] •••.••...•.. 01-028-98
TEST RESULTS [WL-C, WE-C] ....•. 01-028-6 DTC P0563 [WL-C, WE-C] •..•.•..••• 01-028-100
PARAMETER IDENTIFICATION DTC P0602 [WL-C, WE-C] ...•...••.• 01-028-102
(PID) ACCESS [WL-C, WE-C] ....... 01-028-6 DTC P0606, P2530 [WL-C, WE-C] ••... 01-028-102
ON-80ARD DIAGNOSTIC TEST DTC P0607 [WL-C, WE-C] •••.•...... 01-028-102
[WL-C, WE-C] ...........•.....••. 01-028-7 DTC P0610 [WL-C, WE-C] •••.•••.•.. 01-028-103
AFTER REPAIR PROCEDURE DTC P0627 [WL-C, WE-C] ..........• 01-028-104
[WL-C, WE-C] . . • . . . . . • . . . . . • • • . . • 01-028-10 DTC P0628 [WL-C, WE-C] ...••...... 01-028-106
KOEO/KOER SELF TEST DTC P0629 [WL-C, WE-C] ••..•...... 01-028-107
[WL-C, WE-C] .•...•••.....•....•. 01-028-10 DTC P0642 [WL-C, WE-C] •..•••...•• 01-028-109
DTC TA8LE [WL-C, WE-C] ...•....••. 01-028-11 DTC P0643 [WL-C, WE-C] ...•....••• 01-028-112
DTC P0016 [WL-C, WE-C] •...•....•• 01-028-15 DTC P0652 [WL-C, WE-C] ...•....... 01-028-116
DTC P0045 [WL-C, WE-C] ........... 01-028-16 DTC P0653 [WL-C, WE-C] ••....•.... 01-028-119
DTC P0046 [WL-C, WE-C] ........... 01-028-18 DTC P0660 [WL-C, WE-C] •.•..•..... 01-028-123
DTC P0047 [WL-C, WE-C] ........... 01-028-19 DTC P0661 [WL-C, WE-C] ........... 01-028-125
DTC P0048 [WL-C, WE-C] ...•..••..• 01-028-21 DTC P0662 [WL-C, WE-C] ...••...•.. 01-028-127
DTC P0088 [WL-C, WE-C] •...•....•• 01-028-23 DTC P0663 [WL-C, WE-C] •...•.•.... 01-028-128
DTC P0093 [WL-C, WE-C] ........••. 01-028-24 DTC P0664 [WL-C, WE-C] •..••....•. 01-028-130
DTC P0097 [WL-C, WE-C] .....•....• 01-028-25 DTC P0665 [WL-C, WE-C] ...•....•.. 01-028-132
DTC P0098 [WL-C, WE-C] . • . . . . • • . . • 01-028-27 DTC P0685 [WL-C, WE-C] ...•....... 01-028-134
DTC P0102 [WL-C, WE-C] •..••....•• 01-028-29 DTC P0698 [WL-C, WE-C] ....•...... 01-028-136
DTC P0103 [WL-C, WE-C] ........... 01-028-31 DTC P0699 [WL-C, WE-C] •...•...... 01-028-138
DTC P0106 [WL-C, WE-C] ........... 01-028-33 DTC P1196 [WL-C, WE-C] ..........• 01-028-141
DTC P0107 [WL-C, WE-C] . . . . . • . • . . • 01-028-35 DTC P1259 [WL-C, WE-C] ........... 01-028-142
DTC P0108 [WL-C, WE-C] ...•..••..• 01-028-38 DTC P1260 [WL-C, WE-C] •...•..•... 01-028-144
DTC P0112 [WL-C, WE-C] •..••....•. 01-028-41 DTC P1391 [WL-C, WE-C] ••.••...••. 01-028-144
DTC P0113 [WL-C, WE-C] •.......••. 01-028-42 DTC P1392 [WL-C, WE-C] ...•.•..•.• 01-028-147
DTC P0117 [WL-C, WE-C] ..•.....•.. 01-028-44 DTC P1602 [WL-C, WE-C] ...•...•... 01-028-149
DTC P0118 [WL-C, WE-C] .•.....•..• 01-028-46 DTC P1603 [WL-C, WE-C] •...•...... 01-028-149
DTC P0122 [WL-C, WE-C] ...••.•..•• 01-028-48 DTC P1604 [WL-C, WE-C] •..•....••. 01-028-150
DTC P0123 [WL-C, WE-C] ........... 01-028-50 DTC P1621, P1622, P1623,
DTC P0182 [WL-C, WE-C] ........... 01-028-52 P1624 [WL-C, WE-C] ...•.......•... 01-028-150
DTC P0183 [WL-C, WE-C] ..•........ 01-028-54 DTC P1675 [WL-C, WE-C] •...•...... 01-028-151
DTC P0191 [WL-C, WE-C] ......••..• 01-028-56 DTC P1676 [WL-C, WE-C] ••.•.•..••. 01-028-152
DTC P0192 [WL-C, WE-C] ....•....•. 01-028-57 DTC P2135 [WL-C, WE-C] ...•....... 01-028-152
DTC P0193 [WL-C, WE-C] •.......•.. 01-028-59 DTC P2136 [WL-C, WE-C] •...•..•... 01-028-153
DTC P0201 [WL-C, WE-C] ..•..•.•..• 01-028-61 DTC P2143 [WL-C, WE-C] •...•.•.••. 01-028-154
DTC P0202 [WL-C, WE-C] .•....••..• 01-028-62 DTC P2144 [WL-C, WE-C] ...•.•....• 01-028-156
DTC P0203 [WL-C, WE-C] ...••....•. 01-028-64 DTC P2145 [WL-C, WE-C] ...•....... 01-028-158
DTC P0204 [WL-C, WE-C] •.......••. 01-028-66 DTC P2146 [WL-C, WE-C] •.•.•...•.. 01-028-160
DTC P0222 [WL-C, WE-C] ..........• 01-028-68 DTC P2147 [WL-C, WE-C] ••.•....••• 01-028-160
DTC P0223 [WL-C, WE-C] .•....••..• 01-028-71 DTC P2148 [WL-C, WE-C] ..••.•..... 01-028-162
DTC P0227 [WL-C, WE-C] .•.••.•..•• 01-028-74 DTC P2149 [WL-C, WE-C] ....•..•... 01-028-164
DTC P0228 [WL-C, WE-C] ........••. 01-028-76 DTC P2150 [WL-C, WE-C] •...•...••. 01-028-165
DTC P0300 [WL-C, WE-C] ........... 01-028-78 DTC P2151 [WL-C, WE-C] •.••••.•..• 01-028-167
DTC P0301, P0302, P0303, DTC P2227 [WL-C, WE-C] ..••....... 01-028-170
P0304 [WL-C, WE-C] •••.•.•..•..•• 01-028-80 DTC P2228 [WL-C, WE-C] ....•..•... 01-028-170
DTC P0335 [WL-C, WE-C] •...•...••. 01-028-81 DTC P2229 [WL-C, WE-C] •..•..•.•.• 01-028-171
DTC P0340 [WL-C, WE-C] ....•...•.. 01-028-84
01-028-1
ON-BOARD DIAGNOSTIC WIRING DIAGRAM [WL-C, WE-C]
dcf010200000w23
r-------~-o------_{D
-+--+-+LOCK
Hf-I--HH
ACC
IG1
-I::-+-----{ E
IG2
STA DLC
IG-
FEN
KLN
TEN
F
DLC-2
KLN
L----iTEN
PCM
(BUILT INTO
GLOW INDICATOR
BARO SENSOR)
LIGHT
VEHICLE
SPEED SIGNAL
FUEL
INJECTOR
FUEL
INJECTOR
NO.3
FUEL
INJECTOR
NO.2
FUEL
INJECTOR
IAT NO.1
SENSOR
NO.2
DBG 102BWBY01
01-028-2
APP
SENSOR
FUEL PRESSURE
SENSOR
BOOST
SENSOR
CMPSENSOR
ECT
SENSOR
L.!:::t---\
FUEL
CKP SENSOR
TEMPERATURE
SENSOR
EGRVALVE
POSITION
SENSOR PCM
BLOWER '------'
MOTOR
··
1- ............ ..
REFRIGERANT
·····
PRESSURE
SWITCH (LOW)
.. --------- .. - .... _-------- .... ---,
VARIABLE SWIRL :
··· ~~-;-~ ~-+~~ CONTROL :
··· AlC SOLENOID VALVE :
·
···
COMPRESSOR
··· AlC RELAY
··
:AlC
: SWITCH
: THERMO SWITCH
··'- - - - - - - - - - - - - - - - WITH AlC - - - - - - - - - - - - - - - - ~
DBG102BWBY02
01-028-3
..J--f-----i E
STA DLC
IG-
FEN
KLN
TEN
DLC-2
KLN
'----iTEN
CAN_H
CAN_L
PCM
(BUILT INTO
GLOW INDICATOR
LIGHT ~--I--------1f--------(
BARO SENSOR)
VEHICLE
SPEED SIGNAL
FUEL
INJECTOR
FUEL
INJECTOR
NO.3
FUEL
INJECTOR
NO.2
FUEL
INJECTOR
NO.1
DBG102BWBY03
01-028-4
APP
SENSOR
FUEL PRESSURE
SENSOR
BOOST
SENSOR
CMP SENSOR
ECT
SENSOR
L':::':t----;
FUEL CKPSENSOR
TEMPERATURE
SENSOR
EGRVALVE
POSITION
SENSOR PCM
11---+--0 o---+--+-... GLOW

BLOWER L...-_----I
PLUG
RELAY
MOTOR
··
1-"""""" ..
REFRIGERANT
··
··
PRESSURE
SWITCH (LOW)
.. ---------------------------.
VARIABLE SWIRL :
~~-;-~ o--+~~ CONTROL :
SOLENOID VALVE :
···
AlC
COMPRESSOR
···
···· AlC RELAY
··:AlC
:SWITCH
···
··: THERMO SWITCH
··'- - - - - - - - - - - - - - - . WITH AlC· - - - - - - - - - - - - - - -
DBG102BWBY02
01-028-5
FOREWORD [WL-C, WE-C]
dcf010200000w24
• When the customer reports a vehicle malfunction, check the malfunction indicator light (MIL) indication and
diagnostic trouble code (DTC), then diagnose the malfunction according to following flowchart.
If the DTC exists, diagnose the applicable DTC inspection. (See 01-02B-11 DTC TABLE [WL-C, WE-C].)
If the DTC does not exist and the MIL does not illuminate, diagnose the applicable symptom
troubleshooting.
CUSTOMER ARRIVES
~~======~Q~======~~
~------~----------~
WARNING LIGHT' NO WARNING LIGHT'
CHECK FOR °CHECK DTC

PRIORITIZED DTC °ENGINE ON TEST, IDLING TEST
11:: DTC !I
~================={,. WITHOUT DTC
DIAGNOSE BY DTC DIAGNOSE BY SYMPTOM

(ON-BOARD DIAGNOSTIC) (SYMPTOM TROUBLESHOOTING)
°DTCTABLE 1. DIAGNOSTIC INDEX
°DTC 2. QUICK DIAGNOSIS CHART
TROUBLESHOOTING 3. SYMPTOM TROUBLESHOOTING
FLOW
DPE102BW1074
*: Malfunction Indicator Light (MIL), Generator Warning Light, Security Light
PENDING TROUBLE CODES [WL-C, WE-C]

dcf010200000w25
• The MIL is illuminated when a malfunction is detected in two consecutive drive cycles. The code for a failed
system is stored in the PCM memory in the first drive cycle. This code is called the pending code. If the
malfunction is not found in the second drive cycle, the PCM determines that the system returned to normal or
the malfunction was mistakenly detected, and deletes the pending code. If the malfunction is found in the
second drive cycle too, the PCM determines that the system has failed, deletes the pending code, illuminates
the MIL and stores the DTC.
FREEZE FRAME DATA [WL-C, WE-C]

dcf010200000w26
• This is the technical data which indicates the engine's condition at the time of the first malfunction. This data·
will remain in the memory.
READ/CLEAR DIAGNOSTIC TEST RESULTS [WL-C, WE-C]

dcf010200000w27
• This retrieves all stored DTCs in the PCM and clears the DTC, Freeze Frame Data, MIL, Distance Travelled
While MIL and Pending Trouble Codes.
PARAMETER IDENTIFICATION (PID) ACCESS [WL-C, WE-C]

dcf010200000w28
• The PID mode allows access to certain data values, analog and digital inputs and outputs, calculated values
and system status information. Since PID values for output devices are PCM internal data values, inspect each
device to identify which output devices are malfunctioning.
01-028-6
ON-BOARD DIAGNOSTIC TEST [WL-C, WE-C]
dcf010200000w15
DTC Reading Procedure

Using PDS/IDS
1. Connect the PDS/IDS to the DLC-2.
2. After the vehicle is identified, select the following
items from the initial screen of the PDS/IDS.
• When using the IDS (notebook PC)
1. Select the "Toolbox" tab.
2. Select "SelfTest".
3. Select "Module".
4. Select "PCM".
• When using the PDS (pocket PC)
1. Select "Module Tests".
2. Select "PCM".
3. Then, select the "Retrieve CMDTCs" and perform
procedures according to directions on the PDSI
IDS screen.
4. Verify the DTC according to the directions on the PDS/IDS screen.
• If any DTCs are displayed, perform troubleshooting according to the corresponding DTC inspection.
5. After completion of repairs, clear all DTCs stored in the PCM, while referring to "AFTER REPAIR
PROCEDURE".
Using WDS
1. Perform the necessary vehicle preparation and visual inspection.
2. Connect the WDS to the DLC-2. r'---------------------,
3. Retrieve the DTCs using the WDS.
DBG110BWBA01
Pending Trouble Code Access Procedure

Using PDS/IDS
3. Select "Module".
4. Select "PCM".
2. Select "PCM".
DBG110BWBA01
IDS screen.
4. Retrieve the pending trouble codes according to the directions on the PDS/IDS screen.
01-028-7
Using WDS
2. Connect the WDS to the DLC-2. ,-------------------,
3. Retrieve the pending trouble codes using the
WDS.
DBG110BWBA01
Freeze Frame PID Data Access Procedure

Using PDSIIDS
items from the initial screen of the PDS/IDS .
3. Select "Module".
4. Select "PCM" .
2. Select "PCM".
DBG110BWBA01
procedures according to directions on the PDS/
IDS screen.
4. Retrieve the freeze frame PID data according to the directions on the PDS/IDS screen.
Using WDS
2. Connect the WDS to the DLC-2. ,-------------------,
3. Record the freeze frame PID data using the WDS.
DBG110BWBA01
PID/DATA Monitor And Record Procedure
Note
• The PID/DATA MONITOR function monitors the calculated value of the input/output signals in the PCM.
Therefore, an output device malfunction is not directly indicated as a malfunction of the monitored value
for the output device. If a monitored value of an output device is out of specification, inspect the monitored
value of the input device related to the output control.
01-028-8
Using PDSIIDS
2. Select "DataLogger".
3. Select "Module".
4. Select "PCM".
2. Select "PCM".
3. Select the PID from the PID table.
4. Verify the PID data according to the directions on
the PDS/IDS screen.
Using WDS
2. Connect the WDS to the DLC-2. ,--------------------,
3. Access and monitor the PIDs using the WDS.
DBGll0BWBAOl
Simulation Function Procedure

USing PDS/IDS
1. Connect the PDS/I DS to the DLC-2.
1. Select the ''Toolbox'' tab.
2. Select "Data Logger" .
3. Select "Module".
4. Select "PCM".
2. Select "PCM".
DBGll0BWBAOl
3. Select the simulation items from the PID table.
4. Perform the simulation function, inspect the
operations for each parts.
• If there is no operation sound from the relay, motor, and solenoid after the simulation function inspection is
performed, it is possible that there is an open or short circuit in the wiring harness, relay, motor or solenoid,
or sticking and operation malfunction.
01-028-9
Using WDS
2. Connect the WOS to the OLC-2. r---------------------,
3. Select the simulation items from the PIO table.
• If there is no operation sound from the relay,
motor, and solenoid after the simulation
function inspection is performed, it is possible
that there is an open or short circuit in the
wiring harness, relay, motor or solenoid, or
sticking and operation malfunction.
DBG110BWBA01
AFTER REPAIR PROCEDURE [WL-C, WE-C]

dcf010200000w16
Using PDS/IDS
1. Connect the POS/IOS to the OLC-2.
items from the initial screen of the POS/IOS.
• When using the lOS (notebook PC)
3. Select "Module".
4. Select "PCM".
• When using the POS (pocket PC)
2. Select "PCM".
DBG110BWBA01
3. Verify the OTC according to the directions on the
POS/IOS screen.
4. Press the clear button on the OTC screen to clear the OTC.
5. Verify that no OTCs are displayed.
Using WDS
1. Connect the WOS to the DLC-2.
2. Turn the engine switch to the ON position.
(Engine off)
3. Record OTC if retrieved.
4. Erase all diagnostic data using the WOS.
DBG110BWBA01
KOEO/KOER SELF TEST [WL-C, WE-C]

dcf01020000Ow17
Using PDS/IDS
1. Connect the POS/IOS to the OLC-2.
items from the initial screen of the POS/IOS.
3. Select "Module".
4. Select "PCM".
2. Select "PCM".
DBG110BWBA01
01-028-10
3. Then, select the "KOEO On Demand SelfTest" or "KOER On Demand SelfTest" and perform procedures
according to directions on the PDS/IDS screen.
4. Verify the DTC according to the directions on the PDS/IDS screen.
5. 'After completion of repairs, clear all DTCs stored in the PCM, while referring to "AFTER REPAIR
PROCEDURE".
UsingWDS
2. Connect the WDS to the DLC-2. ,--------------------,
3. Retrieve the KOEO/KOER DTCs using the WDS.
01-028-11
DTC TABLE[WL-C, WE-C]
id0102c4801500
x: Applicable - : Not applicable

Self-
test Memory
DTC Condition MIL DC Page
function
type*1
POO16 CKp·CMP correlation ON 1 C/R x -
Variable boost control (VBC) solenoid valve
POO45
control circuit open
ON 1 ClaiR x -
POO46
circuit rangelperformance malfunction
ON 1 ClaiR x -
POO47
control circuit low input
ON 1 ClaiR x -
POO48
control circuit high input
ON 1 ClaiR x -
POO88 Fuel pressure system too high ON 1 C x -
POO93 Fuel system leak detection ON 1 C x -
Intak~ air temperature (IAT) sensor No.2 circuit
POO97
low input
ON 1 ClaiR x -
Intake air temperature (IAT) sensor No.2 circuit
POO98 ON 1 ClaiR x -
high input
Mass air flow (MAF) sensor rangelperformance
P0101
problem
ON 2 - x -
P0102 Mass airflow (MAF) sensor circuit low input ON 1 C/R x -
P0103 Mass airflow (MAF) sensor circuit high input ON 1 C/R x -
P0106 Boost sensor rangelperformance malfunction ON 1 C x -
P0107 Boost sensor circuit low input ON 1 ClaiR x -
P0108 Boost sensor circuit high input ON 1 ClaiR x -
Intake air temperature (IAT) sensor No.1 rangel (See 01·02C·9 DTC
P0111 ON 2 C x
perfomance malfunction P0111 [WL·C, WE-C].)
P0112
low input
ON 1 ClaiR x -
P0113 ON 1 ClaiR x -
high input
Engine coolant temperature (ECT) sensor rangel
P0116
performance problem
ON 2 - x -
Engine coolant temperature (ECT) sensor circuit
P0117
low input
ON 1 ClaiR x -
Engine coolant temperature (ECT) sensor circuit
P0118
high input
ON 1 ClaiR x -
Accelerator pedal position (APP) sensor No.1
P0122
circuit low input
ON 1 ClaiR x -
P0123
circuit high input
ON 1 ClaiR x -
P0182 Fuel temperature sensor circuit low input ON 1 ClaiR x -
P0183 Fuel temperature sensor circuit high input ON 1 ClaiR x -
Fuel pressure sensor rangelperformance
P0191
malfunction
ON 1 a x -
P0192 Fuel pressure sensor circuit low input ON 1 ClaiR x -

P0193 Fuel pressure sensor circuit high input ON 1 ClaiR x -
P0201 Fuel injector No.1 circuit openlshort ON 1 C/R x -
P0203 Fuel injector NO.3 circuit openlshort ON 1 C/R x -
P0222
circuit low input
ON 1 ClaiR x -
P0223
circuit high input
ON 1 ClaiR x -
P0227 Idle switch circuit low input ON 1 C x -
P0228 Idle switch circuit high input ON 1 C x -
01-028-12
Self-
test Memory
function
type*1
P0300 Random misfire detected ON 2 C/R x -
P0301 Cylinder No.1 misfire detection ON 2 C/R x -
Crankshaft position (CKP) sensor circuit
P0335
malfunction
ON 1 C/R x -
Camshaft position (CMP) sensor circuit
P0340
malfunction
ON 1 C/R x -
P0380 Glow plug relay circuit malfunction ON 1 cia x -
P0401 EGR flow insufficient detected ON 2 C x -
P0402 EGR flow excessive detected ON 2 C x -
P0403 EGR solenoid valve circuit malfunction ON 1 ClaiR x -
P0404 EGR valve stuck ON 2 C/R x -
P0405 EGR valve position sensor circuit low input ON 1 ClaiR x -
P0406 EGR valve position sensor circuit high input ON 1 ClaiR x -
P0489 EGR solenoid valve control circuit low input ON 1/2 cia x -
P0490 EGR solenoid valve control circuit high input ON 1/2 cia x -
P0500 VSS circuit malfunction ON 2 C x -
P0562 Battery voltage low input ON 1 ClaiR x -
P0563 Battery voltage high input ON 1 ClaiR x -
P0602 PCM programming error ON 1 - x -
P0606 PCM malfunction ON 1 ClaiR x -
P0607 PCM performance problem ON 1/2 ClaiR x -
P0610 PCM vehicle options error ON 1 - x -
P0627 Fuel metering valve control circuit open ON 1 C/R x -
P0628 Fuel metering valve control circuit low input ON 1 C/R x -
P0629 Fuel metering valve control circuit high input ON 1 C/R x -
Fuel pressure sensor and boost sensor 5 V
P0642
circuit low input
ON 1 ClaiR x -
Fuel pressure sensor and boost sensor 5 V
P0643
circuit high input
ON 1 ClaiR x -
P0652 CMP sensor and APP sensor 5 V circuit low input ON 1 ClaiR x -
CMP sensor and APP sensor 5 V circuit high
P0653
input
ON 1 ClaiR x -
Intake shutter solenoid valve (half) control circuit
P0660
open
ON 1 cia x -
P0661 ON 1 cia x -
low input
P0662
high input
ON 1 cia x -
Intake shutter solenoid valve (full) control circuit
P0663
open
ON 1 cia x -
"P0664
low input
ON 1 cia x -
P0665
high input
ON 1 cia x -
P0685 Main relay control circuit open - - - - -
P0698 EGR valve position sensor 5 V circuit low input ON 1 C/O/R x -
P0699 EGR valve position sensor 5 V circuit high input ON 1 C/O/R x -
P1196 Key off voltage high input - - - - -
P1259 IMMOBILIZER to PCM signal error - - cia - -
P1260 Theft detected Vehicle immobilizer - - cia - -
P1391 Glow plug control circuit low input ON 1 cia x -
01-028-13
Self-
test Memory
function
type*1
P1392 Glow plug control circuit high input ON 1 CIO x -
(See 01-02C-11 DTC
P1528 Exhaust shutter solenoid valve circuit problem - 1 CIO - P1528[WL-C, WE-C).)
P1602 Immobilizer/PCM communication error - - CIO - -
P1603 ID Number Unregistered - - CIO - -
P1604 Code word unregistered - - CIO - -
P1621 Immobilizer code word does not match - - CIO - -
P1622 Immobilizer ID does not match - - CIO - -
P1623 Immobilizer code word/lD number write failure - - CIO - -
P1624 Anti-theft system - - CIO - -
P1675 Injection quantity adjustment value writing error ON 1 0 x -
Injection quantity adjustment value checksum
P1676
error
ON 1 0 x -
P1812 RFW Lock solenoid valve circuit failure -
P1813 RFW Lock solenoid valve open circuit -
P1814 RFW Lock solenoid valve circuit/short to battery -
P1815 RFW Lock solenoid valve circuit/short to ground -
P1878 RFW Free solenoid valve circuit failure -
P1879 RFW Free solenoid valve open circuit -
P1880 RFW Free solenoid valve circuit/short to battery -
P1885 RFW Free solenoid valve circuit/short to ground -
Variable swirl control (VSC) solenoid valve circuit
P2008
open
ON 1 CIO x -
P2009
low input
ON 1 CIO x -
P2010
high input
ON 1 CIO x -
P2135
No.2 voltage correlation problem
ON 1 C/O/R x -
P2136
idle switch voltage correlation problem
ON 1 C/O/R x -
P2143 EGR control solenoid valve control circuit open ON 1/2 CIO x -
EGR control solenoid valve control circuit low
P2144
input
ON 1/2 C/O/R x -
EGR control solenoid valve control circuit high
P2145
input
ON 1/2 C/O/R x -
Fuel injector No.1 and No.4 power supply circuit
P2146
malfunction
ON 1 C/R x -

P2147
low input
ON 1 C/R x -
P2148
high input
ON 1 C/R x -
P2149
malfunction
ON 1 C/R x -
P2150 ON 1 C/R x -
low input
P2151
high input
ON 1 C/R x -
SARO sensor circuit rangelperformance
P2227
malfunction
ON 1 C x -
P2228 SARO sensor circuit low input ON 1 C/O/R x -
P2229 SARO sensor circuit high input ON 1 C/O/R x -
P2263 Air charging system performance malfunction - 1 C x -
P2530 PCM (engine switch circuit) malfunction ON 1 0 x -
*1 : C; CMDTC self test, 0; KOEO self test, R; KOER self test
01-028-14
DTC P0016 [WL-C, WE-C]

dcf010200001w01
DTC P0016 CKP-CMP correlation

• The PCM monitors the input pulses from the CKP and CMP sensors. If the pick-up timing input pulses do
DETECTION
not match each other, the PCM determines that the camshaft position does not coincide with the crankshaft
CONDITION
position.
• Poor connection of connector
• CMP sensor malfunction
• CKP sensor malfunction
POSSIBLE • Damaged or scratched CMP sensor pulse wheel
CAUSE • Damaged or scratched CKP sensor pulse wheel
• Foreign material on CMP sensor
• Foreign material on CKP sensor
• Improper valve timing
Record the FREEZE FRAME DATA on the repair order,

• Has the FREEZE FRAME DATA been then go to the next step.
recorded?
2 VERIFY RELATED REPAIR INFORMATION Yes Perform the repair or diagnosis according to the available
AVAILABILITY repair information.
• Verify related service repair information • If the vehicle is not go to the next
availability. No Go to the next step.
• Is any related repair information available?
3 INSPECT CMP SENSOR CONNECTOR FOR
POOR CONNECTION
• Turn the engine switch off.
• Disconnect the CMP sensor connector.
• Inspect for poor connection (such as damaged/
pulled-out pins, corrosion).
• Is there any malfunction?
4 INSPECT CMP SENSOR FOR FOREIGN Yes Remove foreign material from the CMP sensor, then go to
MATERIAL Step 13.
• Remove the CMP sensor. No Go to the next step.
• Inspect the CMP sensor for foreign material.
• Is there any foreign material on the CMP
sensor?
5 INSPECT CMP SENSOR PULSE WHEEL Yes Replace the camshaft, then go to Step 13.
• Visually inspect the CMP sensor pulse wheel. (See 01-10B-9 CYLINDER HEAD GASKET
• Is there any damage or scratching to the CMP REPLACEMENT [WL-C, WE-C].)
sensor pulse wheel?
6 INSPECT CMP SENSOR
• Inspect the CMP sensor.
(See 01-40B-37 CAMSHAFT POSITION
(CMP) SENSOR INSPECTION [WL-C, WE-
C].)
• Is the CMP sensor normal?
7 INSPECT CKP SENSOR CONNECTOR FOR
POOR CONNECTION
• Disconnect the CKP sensor connector.
8 INSPECT CKP SENSOR FOR FOREIGN Yes Remove foreign material from the CKP sensor, then go to
MATERIAL Step 13.
• Remove the CKP sensor. No Go to the next step.
• Inspect the CKP sensor for foreign material.
• Is there any foreign material on the CKP
sensor?
9 INSPECT CKP SENSOR PULSE WHEEL Yes Replace the CKP sensor pulse wheel, then go to Step 13.
• Visually inspect the CKP sensor pulse wheel. (See 01-10B-7 TIMING BELT REMOVAUINSTALLATION
• Is there any damage or scratching to the CKP [WL-C, WE-C].)
sensor pulse wheel?
01-028-15

10 INSPECT CKP SENSOR Yes Go to the next step.
• Inspect the CKP sensor. No Replace the CKP sensor, then go to Step 13.
(See 01-40B-39 CRANKSHAFT POSITION (See 01-40B-38 CRANKSHAFT POSITION (CKP)
(CKP) SENSOR INSPECTION [WL-C, WE-C].) SENSOR REMOVAUINSTALLATION [WL-C, WE-C].)
• Is the CKP sensor normal?
11 INSPECT PCM CONNECTOR FOR POOR Yes Repair or replace the terminal, then go to Step 13.
CONNECTION No Go to the next step.
• Disconnect the PCM sensor connector.
12 INSPECT VALVE TIMING Yes Go to the next step.
• Inspect valve timing. No Adjust the valve timing properly, then go to the next step.
(See 01-10B-7 TIMING BELT REMOVAU (See 01-10B-7 TIMING BELT REMOVAUINSTALLATION
INSTALLATION [WL-C, WE-C].) [WL-C, WE-C].)
• Is valve timing normal?
13 VERIFY TROUBLESHOOTING OF DTC POO16 Yes Replace the PCM, then go to the next step.
COMPLETED . (See 01-40B-9 PCM REMOVAUINSTALLATION [WL-C,
• Turn the engine switch off. WE-C].)
• Make sure to reconnect all disconnected No Go to the next step.
connectors.
• Turn the engine switch to the ON position
(Engine off).
• Clear the DTC from the memory using the i
current diagnostic tool.
• Run the vehicle under the FREEZE FRAME
DATA stored condition.
• Is the same DTC present?
14 VERIFY AFTER REPAIR PROCEDURE Yes Go to the applicable DTC inspection.
• Perform the "After Repair Procedure". (See 01-02B-11 DTC TABLE [WL-C, WE-C].)
(See 01-02B-10 AFTER REPAIR No DTC troubleshooting completed.
PROCEDURE [WL-C, WE-C].)
• Are any DTCs present?

dcf01 0200001 w02
DTC POO45Variable boost control (VBC) solenoid valve control circuit open
DETECTION •
The PCM monitors the VBC solenoid valve control signal. If the VBC solenoid valve control voltage is less
than 5 V for 2 s when the VBC solenoid valve is off, the PCM determines that there is a VBC solenoid
CONDITION
valve control circuit malfunction (open circuit).
• VBC solenoid valve malfunction
POSSIBLE • Connector or terminal malfunction
CAUSE • Open circuit in wiring harness between main relay and VBC solenoid valve terminal A
• Open circuit in wiring harness between VBC solenoid valve terminal Band PCM terminal 178
• PCM malfunction
01-028-16
VBC SOLENOID VALVE PCM

MAIN RELAY
@@ ® ®
t-*--------~H178
VBC SOLENOID VALVE

PCM
WIRING HARNESS-SIDE
WIRING HARNESS-SIDE CONNECTOR
CONNECTOR
Diagnostic procedure
1 VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to the next step.
RECORDED No Record the FREEZE FRAME DATA on the repair order,
• Has FREEZE FRAME DATA been recorded? then go to the next step.
2 VERIFY RELATED REPAIR INFORMATION Yes Perform repair or diagnosis according to the available
• Verify related service repair information • If the vehicle is not repaired, go to the next step.
3 VERIFY CURRENT SIGNAL STATUS: IS Yes Go to the next step.
CONCERN INTERMITTENT OR CONSTANT? No Intermittent concern exists.
• Connect the current diagnostic tool to the DLC- Perform the "INTERMITTENT CONCERN
2. TROUBLESHOOTING".
• Clear the DTC from the PCM memory using (See Of-03B-60 INTERMITTENT CONCERN
the current diagnostic tool. TROUBLESHOOTING [WL-C, WE-C].)
4 INSPECT VBC SOLENOID VALVE CONNECTOR Yes Repair or replace the terminal, then go to Step 9.
FOR POOR CONNECTION No Go to the next step.
• Disconnect the VBC solenoid valve connector.
5 INSPECT VBC SOLENOID VALVE CONTROL Yes Go to the next step.
CIRCUIT FOR OPEN CIRCUIT No Repair or replace the wiring harness for a possible open
• Turn the engine switch to the ON position circuit, then go to Step 9.
(Engine off).
• Measure the voltage between VBC solenoid
valve terminal A (wiring harness-side) and
body ground.
• Is the voltage B+?
6 INSPECT VBC SOLENOID VALVE Yes Replace the VBC solenoid valve, then go to Step 9.
• Inspect the VBC solenoid valve. (See 01-13B-3INTAKE-AIR SYSTEM REMOVAU
(See 01-13B-6 VARIABLE BOOST CONTROL INSTALLATION [WL-C, WE-C].)
(VBC) SOLENOID VALVE INSPECTION [WL- No Go to the next step.
C, WE-C).)
01-028-17

..
CONNECTION
Turn the engine switch off .
• Disconnect the PCM connector.
No Go to the next step.

8 INSPECT VBC SOLENOID VALVE CONTROL Yes Go to the next step.
• Turn the engine switch off. circuit, then go to the next step.
• Inspect for continuity between VBC solenoid
valve terminal B (wiring harness-side) and
PCM terminal 178 (wiring harness-side).
• Is there continuity?
9 VERIFY TROUBLESHOOTING OF DTC POO45 Yes Replace the PCM, then go to the next step.
COMPLETED (See 01-40B-9 PCM REMOVAUINSTALLATION [WL-C,
WE-C].)
connectors.
(Engine offt
• ylear the 0+9. from the memory using the
current diagrltYstic tool.
, __ '~\1. <.- • Is the same DTC pre,l:>ent?
• Perform the "After Repair Procedure". (See 01-02B-11 DTC TABLE [WL-C, WE-C).)

dcf01 0200001 w03
DTC POO46 Variable boost control (VBC) solenoid valve circuit range/performance malfunction
DETECTION • The PCM monitors the driver IC temperature of the VBC solenoid valve. If the temperature of the VBC
solenoid valve driver IC in the PCM exceeds 150 °C{320 OF} while the VBC solenoid valve is operating, the
CONDITION
PCM determines that there is a VBC solenoid value malfunction.
POSSIBLE • VBC solenoid valve malfunction
CAUSE • PCM malfunction
recorded?
• Connect the current diagnostic tool to the DLC- Perform the "INTERMITTENT CONCERNS
• Clear the DTC from the PCM memory using (See 01-03B-60 INTERMITTENT CONCERN
01-028-18

4 INSPECT OPERATION OF VBC SOLENOID Yes Go to the next step.
VALVE No Clean the guide blade actuator, then go to the next step.
• Connect the current diagnostic tool to DLC-2.
• Start the engine at idle.
• Access VBCV PID.
• Visually inspect the guide blade actuator (rod)
operation using the VBCV PID of simulation
function.
• Does the guide blade actuator (rod) move
smoothly?
5 INSPECT VBC SOLENOID VALVE Yes Replace the VBC solenoid valve, then go to the next step.
• Inspect the VBC solenoid valve. No Go to the next step.
(See 01-13B-6 VARIABLE BOOST CONTROL
(VBC) SOLENOID VALVE INSPECTION [WL-
C, WE-C].)
6 VERIFY THAT DTC P0046 TROUBLESHOOTING Yes Replace the PCM, then go to the next step.
IS COMPLETED (See 01-40B-9 PCM REMOVAUINSTALLATION [WL-C,
• Turn the engine switch off. WE-C).)
connectors.
(Engine off).
• Clear the DTC from the memory using the

dcf01 0200001 w04
DTC POO47 Variable boost control (VBC) solenoid valve control circuit low input
• The PCM monitors the VBC solenoid valve control signal. If the PCM turns VBC solenoid valve off but the
DETECTION
voltage at PCM terminal 178 still remains low, the PCM determines that the VBC solenoid valve circuit has
CONDITION
a malfunction (circuit short to ground).
CAUSE • Short to ground in the wiring harness between VBC solenoid valve terminal Band PCM terminal 178
• PCM malfunction
01-028-19
DTC P0047 I Variable boost control (VBC) solenoid valve control circuit low input

MAIN RELAY
T @
~
® @ @ rJ)
S
WIRING HARNESS-SIDE WIRING HARNESS-SIDE
CONNECTOR CONNECTOR
w] 124 123 122 121 120 119 118 117 116 115 114 113112 111 110 109 108107 106 105 104 103 102 101
148 147 146 145 144 143 142 141 140 139 138 137136 135 134 133 132131 130 129 128 127 126 125
172 171 170 169 168 167 166 165 164 163 162 161160 159 158 157 156155 154 153 152 151 150 149
196 195 194 193 192 191 190 189 188 187 186 185184 183 182 181 180179 178 177 176 175 174 173
I Gt~ I I Gt~ I
recorded?
4 INSPECT VBC SOLENOID VALVE CONNECTOR Yes Repair or replace the terminal, then go to Step 8.
C, WE-C].)
6 INSPECT VBC SOLENOID VALVE CONTROL Yes Repair or replace the wiring harness for a short to ground
CIRCUIT FOR SHORT TO GROUND between VBC solenoid valve terminal A (wiring harness-
• Turn the engine switch off. side) and PCM terminal 178, then go to Step 8.
• Disconnect the PCM connector and VBC No Go to the next step.
solenoid valve connector.
• Inspect for continuity between VBC solenoid
body ground.
01-028-20

7 INSPECT PCM CONNECTOR FOR POOR Yes Repair or replace the terminal, then go to the next step.
connectors.
(Engine off).
• the same DTC present?
Is

dcf010200001w05
DTC P0048 Variable boost control (VBC) solenoid valve control circuit high input
• The PCM monitors the VBC solenoid valve control signal. If the PCM turns VBC solenoid valve on but the
DETECTION
current at PCM terminal 178 still remains high, the PCM determines that the VBC solenoid valve circuit has
CONDITION
a malfunction (circuit short to power supply).
CAUSE • Short to power supply in the wiring harness between VBC solenoid valve terminal Band PCM terminal 178
• PCM malfunction

MAIN RELAY
® ® ® ®
'-----"'*1 A ~--------~178

CONNECTOR CONNECTOR
01-028-21
recorded?
4 CLASSIFY MALFUNCTION FOR INSPECT VBC Yes Go to the next step.
SOLENOID VALVE CONTROL CIRCUIT OR No Go to Step 7.
OTHER
(Engine off).
• Measure the voltage between VBC solenoid
body ground.
5 INSPECT VBC SOLENOID VALVE CONTROL Yes Repair or replace the wiring harness for a short to power
CIRCUIT FOR SHORT TO POWER SUPPLY between VBC solenoid valve terminal A and PCM terminal
• Turn the engine switch off. 178, then go to Step 9.
• Disconnect the PCM connector and VBC No Go to the next step.
solenoid valve connector.
(Engine off).
• Measure the voltage between PCM terminal
178 (wiring harness-side) and body ground.
6 INSPECT PCM CONNECTOR FOR POOR Yes Repair or replace the terminal, then go to Step 9 .
CONNECTION No Go to Step 9.
C, WE-C].)
8 INSPECT VBC SOLENOID VALVE CONNECTOR Yes Repair or replace the terminal, then go to the next step.
01-028-22
THAT DTC P0048 TROUBLESHOOTING Yes Replace the PCM, then go to the next step.
• Turn the engine switch off. I--_+-W_E_-C-=]c..:,.)_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _---l
connectors.
(Engine off).
DTC P0088 Fuel pressure system too high

• The PCM monitors the fuel pressure in the common rail from the fuel pressure sensor while the engine is
DETECTION
running. If the fuel pressure is more than the preprogrammed criteria, the PCM determines that the fuel
CONDITION
pressure is too high.
• Supply pump malfunction
• Fuel pressure sensor malfunction
POSSIBLE
• Fuel pressure limiter malfunction
CAUSE
• Fuel pipe improper connection on fuel tank
• PCM malfunction
AVAILABILITY Service Information.
• Verify related service information availability. • If the vehicle is not repaired, go to the next step.
• Is any related repair information available? No Go to the next step.
• Clear the DTC from the PCM memory using
the current diagnostic tool.
• Start the engine.
4 IDENTIFY TRIGGER DTC FOR FREEZE FRAME Yes Go to the applicable DTC inspection.
DATA (See 01-02B-11 DTC TABLE [WL-C, WE-C].)
• Is P0628, P0629, P0191, P0192 or P0193 on No Go to the next step.
FREEZE FRAME DATA?
5 INSPECT FUEL PIPE CONNECTION ON FUEL Yes Go to the next step.
TANK No Reconnect fuel pipes properly, then go to Step 9.
• Inspect the fuel pipes for supply and return (See 01-14B-7 Fuel Hose Installation Note.)
connection at fuel tank.
• Are fuel pipes connected properly?
6 INSPECT FUEL LINE Yes Repair or replace suspect fuel line, then go to Step 9.
• Turn the engine switch off. No Go to the next step.
• Inspect for fuel leakage or clogging in the
following fuel lines for each cylinder:
- Supply pump and common rail.
- Common rail and fuel injector
01-028-23

7 INSPECT FUEL PRESSURE SENSOR Yes Replace the common rail, go to Step 9.
• Inspect the fuel pressure sensor. No Go to the next step.
(See 01-40B-33 FUEL PRESSURE SENSOR
INSPECTION [WL-C, WE-C].)
a INSPECT COMMON RAIL Yes Replace the common rail, go to the next step.
• Inspect the common rail. No If DTC pooaa and P0093 are stored together, the possible
• Is there any malfunction? cause could be a supply pump internal failure. Replace the
supply pump, then go to the next step.
(See 01-14B-11 SUPPLY PUMP REMOVAU
INSTALLATION [WL-C, WE-C].)
Go to the next step except for the above case.
9 VERIFY TROUBLESHOOTING OF DTC POO88 Yes Replace the PCM, go to the next step.
• Make sure to reconnect all disconnected WE-C].)
connectors. No Go to the next step.
(See 01-02B-10 AFTER REPAIR No Troubleshooting completed.

dcf01 0200001 w07
DTC POO93 Fuel system leak detection
DETECTION • The PCM monitors the fuel pressure in the common rail from the fuel pressure sensor while the engine is
running. If the fuel pressure is lower than the preprogrammed criteria, the PCM determines that there is
CONDITION
leakage in the fuel system.
• Fuel leakage or clogged fuel line
POSSIBLE • Fuel pressure sensor malfunction
CAUSE • Fuel injector malfunction
• Fuel pipe improper connection on fuel tank
• PCM malfunction
• Verify related Service Information availability. • If the vehicle is not repaired, go to the next step.
4 IDENTIFY TRIGGER DTC FOR FREEZE FRAME Yes Go to the applicable DTC inspection.
DATA (See 01-02B-11 DTC TABLE [WL-C, WE-C].)
• Is P0192 or P0193 on FREEZE FRAME DATA? No Go to the next step.
01-028-24

5 INSPECT FUEL PIPE CONNECTION ON FUEL Yes Go to the next step.
TANK No Reconnect fuel pipes properly, then go to Step 9.
• Inspect the fuel pipes for supply and return (See 01-14B-7 Fuel Hose Installation Note.)
connection at fuel tank.
• Are fuel pipes connected properly?
6 INSPECT FUEL LINE Yes Repair or replace the suspected fuel line, go to Step 9.
• Inspect for fuel leakage or clogging in the
following fuel lines for each cylinder:
- Supply pump and Common rail.
- Common rail and fuel injector.
7 INSPECT FUEL PRESSURE SENSOR Yes Replace the common rail, go to Step 9.
8 INSPECT FUEL INJECTOR Yes Replace the fuel injector, go to the next step.
• Inspect the fuel injector. (See 01-14B-15 FUEL INJECTOR REMOVAU
(See 01-14B-16 FUEL INJECTOR INSTALLATION [WL-C, WE-C].)
INSPECTION [WL-C, WE-C].) No If DTC P0088 and P0093 are stored together, the possible
• Is there any malfunction? cause could be a supply pump internal failure. Replace the
supply pump, then go to the next step.
(See 01-14B-11 SUPPLY PUMP REMOVAU
Go to the next step except for the above case.
9 VERIFY TROUBLESHOOTING OF DTC P0093 Yes Replace the PCM, go to the next step.

dcf01 0200001 wOS
DTC P0097 Intake air temperature (IAT) sensor No.2 circuit low input
DETECTION • The PCM monitors the input signal from intake air temperature sensor No.2. If the voltage from intake air
temperature sensor No.2 is less than 0.1 V for 2 s, the PCM determines that there is a malfunction in the
CONDITION
• IAT sensor No.2 malfunction
CAUSE • Short to ground in wiring harness between IAT sensor No.2 terminal D and PCM terminal 188
• PCM malfunction
01-028-25
IAT SENSOR NO.2 PCM
MAF SENSOR/IAT SENSOR NO.2 PCM

WIRING HARNESS-SIDE CONNECTOR WIRING HARNESS-SIDE CONNECTOR
~EIDfflBIA~ lnlnl~I~I~I~I~IM1Ml~laI6
lN1El~I~I~I~IOOI~IMl~IM
I~~ I
4 INSPECT MAF SENSORIIAT SENSOR NO.2 Yes Repair or replace the terminal, then go to Step 8.
CONNECTOR FOR POOR CONNECTION No Go to the next step.
• Disconnect the MAF sensor/IAT sensor No.2
connector.
5 INSPECT IAT SENSOR NO.2 SIGNAL CIRCUIT Yes Repair or replace the wiring harness for a possible short to
FOR SHORT TO GROUND ground, then go to Step 8.
• Inspect for continuity between IAT sensor No.2
terminal 0 (wiring harness-side) and body
ground.
01-028-26

6 INSPECT IAT SENSOR NO.2 Ves Replace the IAT sensor No.2, then go to Step 8.
• Inspect the IAT sensor No.2. No Go to the next step.
(See 01-40B-23 MASS AIR FLOW (MAF)
SENSOR/INTAKE AIR TEMPERATURE (IAT)
SENSOR NO.2 INSPECTION [WL-C, WE-C].)
7 INSPECT PCM CONNECTOR FOR POOR Ves Repair or replace the terminal, then go to the next step.
8 VERIFV TROUBLESHOOTING OF DTC P0097 Ves Replace the PCM, then go to the next step.
connectors.
(Engine off).
9 VERIFY AFTER REPAIR PROCEDURE Ves Go to the applicable DTC inspection.
PROCEDURE [WL-C, WE-C).}

dcf01 0200001 wOg
DTC POO98Intake air temperature (IAT) sensor No.2 circuit high input
DETECTION •
The PCM monitors the input signal from intake air temperature sensor No.2. If the voltage from intake air
temperature sensor No.2 is more than 4.6 V for 1 s, the PCM determines that there is a malfunction in the
CONDITION
• Connector or terminal malfunction
POSSIBLE • Open circuit in wiring harness between IAT sensor No.2 terminal D and PCM terminal 188
CAUSE • Short to power supply in wiring harness between IAT sensor No.2 terminal D and PCM terminal 188
• Open circuit in wiring harness between IAT sensor No.2 terminal E and PCM terminal 154
• PCM malfunction
01-028-27
DTC P0098 Intake air temperature (IAT) sensor No.2 circuit high input
IAT SENSOR NO.2 PCM
®®
.---~ 0 ~----------------~
®
@
~--4 E ~----------------~
MAF SENSORJIAT SENSOR NO.2 PCM

~ ofITs 1 I)
124123122121 120119118117116115114113112111 110109 108107106
1
191Q1%1%1«1a1g1M1~1~1~1D1~1E1M
E A
I~~ I
1 VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to the next step. \.'

2. TROUBLESHOOTING" .
• Clear the DTC from the PCM memory using (See01-03B-60 INTERMITTENT CONCERN
4 INSPECT MAF SENSORIIAT SENSOR NO.2 Yes Repair or replace the terminal, then go to Step 9.
connector.
FOR SHORT TO POWER SUPPLY power supply, then go to Step 9.
• Turn the engine switch to the ON position No Go to the next step.
(Engine off).
• Measure the voltage between IAT sensor No.2
terminal D (wiring harness-side) and body
ground.
01-028-28

6 INSPECT IAT SENSOR NO.2 Yes Replace the IAT sensor No.2, then go to Step 9.
(See 01-40B-23 MASS AIR FLOW (MAF)
SENSOR/INTAKE AIR TEMPERATURE (IAT)
8 INSPECT IAT SENSOR NO.2 CIRCUIT FOR Yes Go to the next step.
OPEN CIRCUIT No Repair or replace the wiring harness for a possible open
• Turn the engine switch off. circuit, then go to the next step. .
• Inspect for continuity between the following
terminals:
- IAT sensor No.2 terminal E (wiring harness-
side) and PCM terminal 154 (wiring
harness-side)
- IAT sensor No.2 terminal D (wiring harness-
harness-side)
9 VERIFY TROUBLESHOOTING OF DTC P0098 Yes Replace the PCM, then go to the next step.
connectors.
(Engine off).

dcf01 02001 00w07
DTC P0102 Mass airflow (MAF) sensor circuit low input
DETECTION • The PCM calculates the intake air flow amount based on the airflow sensor. If the calculated intake air flow
amount is below 0.44 9/S {0.OS8 Ib/min} for 2.0 s while the engine is running, the PCM determines that
CONDITION
the airflow sensor signal input is low.
• MAF sensor malfunction
POSSIBLE • Open circuit in wiring harness between main relay terminal D and MAF sensor terminal A
CAUSE • Open circuit in wiring harness between MAF sensor terminal C and PCM terminal 190
• Short to ground in wiring harness between MAF sensor terminal C and PCM terminal 190
• PCM malfunction
01-028-29
DTC P0102 IMass airflow (MAF) sensor circuit low input

MAF SENSOR PCM
MAIN RELAY
TERMINAL 0
@ ®
I
~
--"
@ ®® ®
(J)
kS ~ -0
n
P
~
@ ®
MAIN RELAY MAF SENSOR/IAT SENSOR NO.2

WIRING HARNESS-SIDE WIRING HARNESS-SIDE PCM
CONNECTOR CONNECTOR WIRING HARNESS-SIDE CONNECTOR
tffij m;tr
1241123112211211120 119 118 117 116115 114 113112 111 110 109 108 107 106 105 104 103 102 101
oB ~E lofcrBI A
~ 1
4 143 142 141 140 139 138 137136 135 134 133 132 131 130 129 128 127 126 125
168 167 166 165 164 163 162 161160 159 158 157 156 155 154 153 152 151 150 149
196195 19411931192 191 190 189 188 187 186 185184 183 182 181 180 179 178 177 176 175 174 173
I~~ I I~~ I I~~ I

4 INSPECT MAF SENSOR/IAT SENSOR NO.2 Yes Repair or replace the terminal, then go to Step 10.
connector.
5 INSPECT MAF SENSOR POWER CIRCUIT FOR Yes Go to the next step.
• Turn the engine switch to the ON position circuit or short to ground, then go to Step 10.
(Engine off).
• Measure the voltage between MAF sensor
terminal A (wiring harness-side) and body
ground.
01-028-30
Yes Repair or replace the wiring for a possible short to

ground, then go to Step 10.
• Inspect for continuity between MAF sensor
terminal C (wiring harness-side) and body
ground.
7 INSPECT MAF SENSOR Yes Replace the MAF sensor, then go to Step 10.
• Inspect the MAF sensor. (See 01-13B-3INTAKE-AIR SYSTEM REMOVAU
(See 01-40B-23 MASS AIR FLOW (MAF) INSTALLATION [WL-C, WE-C].)
SENSOR/INTAKE AIR TEMPERATURE (IAT) No Go to the next step.
8 INSPECT PCM CONNECTOR FOR POOR
CONNECTION
9 INSPECT MAF SENSOR
OPEN CIRCUIT Repair or replace the wiring harness for a possible open
• Inspect for continuity between MAF sensor
terminal C (wiring harness-side) and PCM
terminal 190 (wiring harness-side).
10 VE TROUBLESHOOTING OF DTC P0102 Yes Replace the PCM, then go to the next step.
connectors.
(Engine off).
11 VERIFY AFTER REPAIR PROCEDURE Yes to the applicable DTC inspection.
• Perform the "After Repair Procedure". 01-02B-11 DTC TABLE [WL-C, WE-C].)
(See 01-02B-10 AFTER REPAIR No

dcf01 02001 OOwOS
DTC P0103 Mass airflow (MAF) sensor circuit high input

• The PCM calculates the intake air flow amount based on the airflow sensor. If the calculated intake air flow
DETECTION amount is above 170 g/s {22 Ib/min} for 1.5 s while driving other than under a fully open throttle condition,
CONDITION and the fuel injection quantity based on the engine speed is below the specification, the PCM determines
that the airflow sensor signal input is high.
• MAF sensor malfunction
CAUSE • Short to power supply in wiring harness between MAF sensor terminal C and PCM terminal 190
• Open circuit in wiring harness between MAF sensor terminal Band PCM terminal 169
• PCM malfunction
01-028-31
DTC P0103 IMass airflow (MAF) sensor circuit high input

MAF SENSOR PCM
MAIN RELAY
TERMINAL 0
fA'
@
-'c, I
J- ~
@ ® rJ)
® -€ ~
P
-0
T f8'
@ @ rJ)
Q
~
t
\J
MAIN RELAY MAF SENSORIIAT SENSOR NO.2

WIRING HARNESS-SIDE WIRING HARNESS-SIDE PCM
CONNECTOR CONNECTOR WIRING HARNESS-SIDE CONNECTOR
tffij
o B ~ I /mBIA~
E
1n1n1ro1~1.1~1.1.1M1.1~1~1M1W1W1~1~1~1M
1.1.1M1a1.1~1W1.1.1~1.1U1M1a1.1~1001n1n
"'' " mil!
124 123 122 121 120 119 11B 117 116 115 114 113 112 111 110 109 10B 107 106 105 104 103 10211011111
1.1Q1%1~1«1g1a1M1W1~1U1D1.1M1M1a1.1~1W
153152151 1
177 176 175 1
I~,,·I I~~ I I~~ I

• Verify related service repair information •
If the vehicle is not repaired, go to the next step.
4 INSPECT MAF SENSOR/IAT SENSOR NO.2 Yes Repair or replace the terminal, then go to Step 9.
connector.
5 INSPECT MAF SENSOR SIGNAL CIRCUIT FOR Yes Repair or replace the wiring harness for a possible short to
SHORT TO POWER SUPPLY power supply, then go to Step 9.
(Engine off).
• Measure the voltage between MAF sensor
ground. I
• Is the voltage more than 4.9 V?
01-028-32

6 INSPECT MAF SENSOR Yes Replace the MAF sensor, then go to Step 9.
• Inspect the MAF sensor. (See 01-13B-3INTAKE-AIR SYSTEM REMOVAU
(See 01-40B-23 MASS AIR FLOW (MAF) INSTALLATION [WL-C, WE-C].)
SENSOR/INTAKE AIR TEMPERATURE (IAT) No Go to the next step.
SENSOR NO.2 INSPECTION [WL-C, WE-Gj.)
8 INSPECT MAF SENSOR GROUND CIRCUIT Yes Go to the next step.
FOR OPEN CIRCUIT No Repair or replace the wiring harness for a possible open
• Inspect for continuity between MAF sensor/IAT
sensor No.2 terminal B (wiring harness-side)
and PCM terminal 169 (wiring harness-side).
• Turn the engine switch off. WE-Gj.)
connectors.
(Engine off).

dcf01 02001 00w09
DTC P0106 Boost sensor range/performance malfunction

• The PCM monitors and compares the intake manifold internal pressure via the boost sensor with the
atmospheric pressure via the barometric pressure sensor (built into PCM) while the engine is not running. If
the difference of these pressure is above 11 kPa {0.11 bar, 1.6 psi}, the PCM determines that there is a
DETECTION boost sensor characteristic malfunction.
CONDITION
Note
• If DTCs P01 06 and P2227 are recorded simultaneously, the PCM determines that there is a boost
sensor and barometric pressure sensor characteristic malfunction.
POSSIBLE • Boost sensor malfunction
01-028-33
DTC P0106 Boost sensor range/performance malfunction
BOOST SENSOR PCM
C ~--------~
o ~--------~189r----~~J
A 1-77----------*l111

WIRING HARNESS-SIDE PCM
CONNECTOR WIRING HARNESS-SIDE CONNECTOR
frill£} I~
124 123 122 121 120 119 118 117 116 115 114 113 112 111 110 109 108 107 106 105 104 103
148 147 146 145 144 143 142 141 140 139 138 137 136 135 134 133 132 131 130 129 128 127
172 171 170 169 168 167 166 165 164 163 162 161 160 159 158 157 156 155 154 153 152 151
196 195 194 193 192 191 190 189 188 187 186 185 184 183 182 181 180 179 178 177 176 175
I~~ I
4 INSPECT BOOST SENSOR Yes Replace the boost sensor, then go to Step 7.
• Inspect the boost sensor. No Go to the next step.
(See 01-40B-27 BOOST SENSOR
connectors.
(Engine off).
01-028-34

DTC P0107 Boost sensor circuit low input

DETECTION • The PCM monitors the input signal from the boost sensor. If the voltage from the boost sensor is less than
CONDITION 0.24 V for 2.0 s, the PCM determines that there is a malfunction in the boost sensor circuit.
• Boost sensor malfunction
• Short to ground in wiring harness between boost sensor terminal C and PCM terminal 133
POSSIBLE
• Short to ground in wiring harness between boost sensor terminal D and PCM terminal 189
CAUSE
• Open circuit in wiring harness between boost sensor terminal. C and PCM terminal 133
• Open circuit in wiring harness between boost sensor terminal D and PCM terminal 189
• PCM malfunction
BOOST SENSORIIAT SENSOR NO.1
'II
mfYi}
124123122121120119118117116115114113112111110 109108107106
129 128 127 126
'" ""ro 150
lU1Q1Ul~1"lalQ1Ml~1.1.lD1Ml.1Mlal.l~1~
lnlnlml~1~1~1~1.lMl~1~1~lW1Wl~1~1~1.1~ 153152151
l"l"lMl.l~l~l~l~lMl~l.l.lMl.l~l~lMl~ln 177 176 175 174
[~~I
• Verity related service repair information • If the vehicle is not repaired, go to the next step.
01-028-35

CONCERN INTERMITIENT OR CONSTANT? No Intermittent concern exists.
4 CLASSIFY 5V CONSTANT VOLTAGE CIRCUIT Yes Go to Step 11.
OR OTHER RELATED MALFUNCTION No Go to the next step.
(Engine off).
• Measure the voltage between the boost
sensor/IAT sensor No.1 terminal C (wiring
harness-side) and body ground.
• Is the voltage 5 V constant voltage?
OR BOOST SENSOR/IAT SENSOR NO.1 No Go to the next step.
RELATED MALFUNCTION
• Disconnect the boost sensor/IAT
, sensor No.1
connector.
(Engine off).
• Measure the voltage between the boost sensor
ground.
6 INSPECT BOOST SENSOR 5V CONSTANT Yes Repair or replace the wiring harness for a possible short to
VOLTAGE CIRCUIT FOR SHORT TO GROUND ground, then go to Step 17.
• Inspect for continuity between the boost
harness-side) and body ground
8 INSPECT BOOST SENSOR 5V CONSTANT Yes Repair or replace the wiring harness for an open circuit,
VOLTAGE CIRCUIT FOR OPEN then go to Step 17.
• Turn the engine switch off. No Go to Step 17.
harness-side) and PCM terminal 133 (wiring
harness-side).
9 INSPECT BOOST SENSOR/IAT SENSOR NO.1 Yes Repair or replace the terminal, then go to Step 17.
• Disconnect the boost sensor/I AT sensor No.1
connector.
10 INSPECT BOOST SENSOR Yes Replace the boost sensor/IAT sensor No.1, then go to Step
• Inspect the boost sensor/IAT sensor No.1. 17.
(See 01-40B-27 BOOST SENSOR No Go to Step 17.
01-028-36

(Engine off).
sensor/IAT sensor No.1 terminal D (wiring
• Is the voltage more than 0.24 V ?
12 INSPECT BOOST SENSOR SIGNAL CIRCUIT Yes Repair or replace the wiring harness for a possible short to
CONNECTION
14 INSPECT BOOST SENSOR SIGNAL CIRCUIT Yes Repair or replace the wiring harness for an open circuit,
FOR OPEN then go to Step 17.
harness-side) .
15 INSPECT BOOST SENSORIIAT SENSOR NO.1
CONNECTOR FOR POOR CONNECTION
• Disconnect the boost sensor/I AT sensor No.1
connector.
16 INSPECT BOOST SENSOR Yes Replace boost sensor/IAT sensor No.1, then go to the
• Inspect the boost sensor/IAT sensor No.1. next step.
(See 01-40B-27 BOOST SENSOR No Go to the next step.
connectors.
(Engine off).
• Are any DTCs
01-028-37
dcf01 02001 00w11
DTC P0108 Boost sensor circuit high input

DETECTION • The PCM monitors the input signal from the boost sensor. If the voltage from the boost sensor is more
CONDITION than 4.9 V for 1.0 s, the PCM determines that there is a malfunction in the boost sensor circuit.
POSSIBLE • Short to power supply in wiring harness between boost sensor terminal 0 and PCM terminal 189
CAUSE • Short to power supply in wiring harness between boost sensor terminal C and PCM terminal 133
• Open circuit in wiring harness between boost sensor terminal A and PCM terminal 111
• PCM malfunction

CONNECTOR
DfYi)
I~~I
(Engine off).
sensor/lAT sensor No.1 terminal C (wiring
01-028-38

OR BOOST SENSORIIAT SENSOR NO.1 No Go to the next step.
RELATED MALFUNCTION
• Disconnect the boost sensor/IAT sensor No.1
connector.
(Engine off).
ground.
CONNECTION No Repair or replace the wiring harness for a possible short to
• Turn the engine switch off. power supply, then go to Step 17.
7 INSPECT BOOST SENSORIIAT SENSOR NO.1 Yes Repair or replace the terminal, then go to Step 17.
connector.
8 INSPECT BOOST SENSOR Yes Replace the boost sensor/IAT sensor No.1, then go to Step
connector.
10 INSPECT BOOST SENSOR GROUND CIRCUIT Yes Go to Step 12.
FOR OPEN CIRCUIT No Repair or replace the wiring harness for an open circuit,
• Turn the engine switch off. then go to the next step.
• Inspect for continuity between boost sensor
terminal A and body ground.
CONNECTION No Repair or replace the wiring harness for an open circuit,
• Turn the engine switch off. then go to the Step 17.
12 CLASSIFY SIGNAL CIRCUIT OR OTHER Yes Go to Step 17.
RELATED MALFUNCTION No Go to the next step.
(Engine off).
• Is the voltage less than 4.9 V ?
01-028-39

13 CLASSIFY SIGNAL CIRCUIT OR BOOST Yes Go to Step 15.
SENSOR/IAT SENSOR NO.1 RELATED No Go to the next step.
MALFUNCTION
• Disconnect the boost sensor/lAT sensor No.1
connector.
(Engine off).
terminal D (wiring harness-side) and body
ground.
connector.
16 INSPECT BOOSTIIAT SENSOR NO.1 SENSOR Yes Replace the boost sensor/IAT sensor No.1, then go to the
• Inspect the boost sensor/IAT sensor No.1. step.
(See 01-40B-27 BOOST SENSOR No Go to the step.
• Is there any maifunction?
connectors.
(Engine off).
• Perform the "After Repair Procedure". (Se.e 01-02B-11 DTC TABLE [WL-C, WE-C].)
PROCEDURE [WL-C, WE-Gj.)
( ..
01-028-40
DlC P0111 [WL-C, WE-C]

id010204803600
DTC P0111 Intake air temperature (IAT) sensor No.1 range/performance malfunction
• The PCM monitors the input signal from the IAT sensor No.1. If the difference between the maximum and
minimum value of the IAT sensor No.1 is less than 0.3 °C {32.6 OF}, the PCM determines that there is a
malfunction in the IAT sensor No.1.
Diagnostic support note
DETECTION • The MIL illuminates if the PCM detects the above malfunction condition in two consecutive drive cycles or
CONDITION in one drive cycle while the DTC for the same malfunction has been stored in the PCM.
• PENDING CODE is available if the PCM detects the above malfunction condition during the first drive
cycle.
• FREEZE FRAME DATA is available.
• The DTC is stored in the PCM memory.
POSSIBLE
CAUSE
• PCM malfunction
IAT SENSOR NO.1 PCM
@
,---~ B ~----------------~~
@
L -_ _~ A H&----------------~~

tumtl 124 123122 121 120 119118 117116 115 114113 112 111 110 109 108107 106 105 104 103 102101
37136 135 134133 132131 130 129 128 127 126125
172 171 170 169 168 167 166 165 164 163 162161 160 159158 157156 155 154 153152 151 150149
196 195194 193 192191 190 189188 187 186 185 184 183182 181 180 179 178 177 176 175 174173
I Gt~ I
01-028-40a
2 VERIFY RELATED SERVICE INFORMATION Yes Perform repair or diagnosis according to the available
AVAILABILITY service information.
• Verify related service information availability. • If the vehicle is not repaired, go to the next step.
• Is any related service information available? No Go to the next step.
• Is the PENDING CODE for this DTC present?
4 INSPECT MAFIIAT SENSOR CONNECTOR FOR Yes Repair or replace the terminal, then go to Step 7.
POOR CONNECTION No Go to the next step.
• Disconnect the MAF/IAT sensor connector.
5 INSPECT IAT SENSOR NO.1 Yes Replace the MAF/IAT sensor, then go to Step 7.
COMPLETED No Go to the next step.
• Make sure to reconnect all disconnected
connectors.
• Start the engine and warm it up completely.
• Perform the Repair Verification Drive Mode. (See 01-02C-6 DTC TABLE[WL-C, WE-C].)
• Are any DTCs present? No DTC troubleshooting completed.
01-02B-40b
dcf01 02001 00w12
DETECTION • The PCM monitors the input signal from IAT sensor No.1. If the voltage from IAT sensor No.1 is less than
CONDITION 0.14 V for 2.0 s, the PCM determines that there is a malfunction in the IAT sensor No.1 circuit.
CAUSE • Short to ground in wiring harness between IAT sensor No.1 terminal Band PCM terminal 141
• PCM malfunction
IAT SENSOR NO.1 PCM

krmtl
I Gt~ I
connector.
01-028-41

• Inspect for continuity between IAT sensor No.1
terminal B (wiring harness-side) and body
ground.
• Inspect the IAT sensor No.1. (See 01-13B-3INTAKE-AIR SYSTEM REMOVAU
(See 01-40B-26 INTAKE AIR TEMPERATURE INSTALLATION [WL-C, WE-C].)
(IAT) SENSOR NO.1 INSPECTION [WL-C, No Go to the next step.
WE-C).)
connectors.
(Engine off).

dcf01 02001 00w13
DTC P0113 Intake air temperature (IAT) sensor No.1 circuit high input
DETECTION • The PCM monitors the input signal from IAT sensor No.1. If the voltage from IAT sensor No.1 is more than
CONDITION 4.90 V for 1.0 s, the PCM determines that there is a malfunction in the IAT sensor No.1 circuit.
POSSIBLE • Open circuit in wiring harness between IAT sensor No.1 terminal Band PCM terminal 141
CAUSE • Short to power supply in wiring harness between IAT sensor No.1 terminal Band PCM terminal 141
• Open circuit in wiring harness between IAT sensor No.1 terminal A and PCM terminal 111
• PCM malfunction
01-028-42
DTC POl13 Intake air temperature (IAT) sensor No.1 circuit high input
IAT SENSOR NO.1 PCM
@@
r---~ B ~--------------~H
®
@
~--~ A ~----------------~

IYmtJ] 61~IMl.l~I~I00I~I~I~I~IU1M1Hl~I~I~lg
01.1~1~IMl~IMl.l~l~ l00I~lnlnlnl~IMln
I~~I
• Verify related service repair information • If the vehicle is not repaired, go to the. next step.
the current diagnostic tool. TROUBLESHOOTING [WL-C, WE-C).)
connector.
• . Is there any malfunction?
5 INSPECT IAT SENSOR NO.1 SIGNAL CIRCUIT Ves Repair or replace the wiring harness for a possible short to
(Engine off).
• Measure the voltage between IAT sensor No.1
ground.
01-028-43

• Inspect the IAT sensor No.1. (See 01-13B-3INTAKE-AIR SYSTEM REMOVAU
(See 01-40B-26 INTAKE AIR TEMPERATURE INSTALLATION [WL-C, WE-C].)
(IAT) SENSOR NO.1 INSPECTION [WL-C, No Go to the next step.
WE-C].)
8 INSPECT IAT SENSOR NO.1 CIRCUIT FOR Yes Go to the next step.
terminals:
- IAT sensor No.1 terminal B (wiring harness-
harness-side)
- IAT sensor No.1 terminal A (wiring harness-
harness-side)
connectors.
(Engine off).

dcf010200100w14
DTC P0117 Engine coolant temperature (ECT) sensor circuit low input
DETECTION • The PCM monitors the input signal from the ECT sensor. If the voltage from the ECT sensor is less than
CONDITION 0.20 V for 2.0 s, the PCM determines that there is a malfunction in the ECT sensor circuit.
• ECT sensor malfunction
CAUSE • Short to ground in wiring harness between ECT sensor terminal Band PCM terminal 167
• PCM malfunction
01-028-44
DTC P0117 Engine coolant temperature (ECT) sensor circuit low input
ECTSENSOR PCM
® @
ECT SENSORIWATER TEMPERATURE PCM

SENDER UNIT WIRING HARNESS-SIDE CONNECTOR
111-1241123112211211120 119 118 117 116 115 114 113112 111 110 109 108 107 106 105 104 103 1021
Iliiir
143 142 141 140 139 138 137136 135 134 133 132131 130 129 128 127 1261
68 167 166 165 164 163 162 161160 159 158 157 156155 154 153 152 151 1501
196195 194 1931192 191 190 189 188 187 186 185184 183 182 181 180179 178 177 176 175 1741
4 INSPECT ECT SENSORIWATER Yes Repair or replace the terminal, then go to Step 8.
TEMPERATURE SENDER UNIT CONNECTOR No Go to the next step.
FOR POOR CONNECTION
• Disconnect the ECT sensor/water temperature
sender unit connector.
5 INSPECT ECT SENSOR SIGNAL CIRCUIT FOR Yes Repair or replace the wiring harness for a possible short to
SHORT TO GROUND ground, then go to Step 8.
• Disconnect the ECT sensor connector.
• Inspect for continuity between ECT sensor
ground.
01-028-45

6 INSPECT ECT SENSOR Yes Replace the ECT sensor, then go to Step 8.
• Inspect the ECT sensor. No Go to the next step.
(See 01-40B-35 ENGINE COOLANT
TEMPERATURE (ECT) SENSOR
connectors.
(Engine off).

dcf01 02001 00w15
DTC P0118 Engine coolant temperature (ECT) sensor circuit high input
DETECTION • The PCM monitors the input signal from the ECT sensor. If the voltage from the ECT sensor is more than
CONDITION 4.91 V for 1.0 s, the PCM determines that there is a malfunction in the ECT sensor circuit.
• ECT sensor malfunction
POSSIBLE • Open circuit in wiring harness between ECT sensor terminal Band PCM terminal 167
CAUSE • Short to power supply in wiring harness between ECT sensor terminal Band PCM terminal 167
• Open circuit in wiring harness between ECT sensor terminal A and PCM terminal 156
• PCM malfunction
01-028-46
ECT SENSOR PCM
@@
® @
ECT SENSORIWATER TEMPERATURE PCM

SENDER UNIT WIRING HARNESS-SIDE CONNECTOR
124 123 122 121 120119 118 117 116 115 114 113112 111 110109 108 107 106 105 104 103 102 101
148 147 146 145 144143 142 141 140 139 138 137136 135 134133 132131 130 129 128 127 126 125
172 171 170 169 168 167 166 165 164 163 162 161160 159 158157 156155 154 153 152 151 150 149
196 195 194 193 192191 190 189 188 187 186 185184 183 182181 180179 178 177 176 175 174 173
4 INSPECT ECT SENSOR! WATER Yes Repair or replace the terminal, then go to Step 9.
TEMPERATURE SENDER UNIT CONNECTOR No Go to the next step.
FOR POOR CONNECTION
• Disconnect the ECT sensor/ water temperature
sender unit connector.
5 INSPECT ECT SENSOR SIGNAL CIRCUIT FOR Yes Repair or replace the wiring harness for a possible short to
SHORT TO POWER SUPPLY power supply, then go to Step 9.
(Engine off).
• Measure the voltage between ECT sensor
ground.
01-028-47

6 INSPECT ECT SENSOR Yes Replace the ECT sensor, then go to Step 9.
• Inspect the ECT sensor. No Go to the next step.
(See 01-40B-35 ENGINE COOLANT
TEMPERATURE (ECT) SENSOR
8 INSPECT ECT SENSOR CIRCUIT FOR OPEN Yes Go to the next step.
CIRCUIT No Repair or replace the wiring harness for a possible open
terminals:
- ECT sensor terminal B (wiring harness-side)
and PCM terminal 167 (wiring harness-side)
- ECT sensor terminal A (wiring harness-side)
connectors.
(Engine off).

dcf010200100w16
DTC P0122 Accelerator pedal position (APP) sensor No.1 circuit low input
DETECTION • The PCM monitors the input signal from APP sensor No.1. If the voltage from APP sensor No.1 is less
than 0.29 V for 0.5 s when the APP sensor No.1 power supply voltage is normal, the PCM determines that
CONDITION
there is a malfunction in the APP sensor No.1 circuit.
• APP sensor No.1 malfunction
POSSIBLE • Open circuit in wiring harness between APP sensor No.1 terminal A and PCM terminal 213
CAUSE • Short to ground in wiring harness between APP sensor No.1 terminal A and PCM terminal 213
• Open circuit in wiring harness between APP sensor No.1 terminal Band PCM terminal 222
• Short to ground in wiring harness between APP sensor No.1 terminal Band PCM terminal 222
• PCM malfunction
01-028-48
APP SENSOR NO.1 PCM -
@ ®® (j)
A
@ ®® (j)
® B
@ (j)
D
APPSENSOR PCM
4 INSPECT APP SENSOR CONNECTOR FOR Yes Repair or replace the terminal, then go to Step 9.
• Disconnect the APP sensor connector.
01-028-49

5 INSPECT APP SENSOR NO.1 CIRCUIT FOR Yes Repair or replace the wiring harness for a possible short to
terminals and body ground:
- APP sensor No.1 terminal A (wiring
- APP sensor No.1 terminal B (wiring
6 INSPECT APP SENSOR NO.1 Yes Replace the APP sensor, then go to Step 9.
• Inspect the APP sensor No.1. No Go to the next step.
(See 01-40B-28 ACCELERATOR PEDAL
POSITION (APP) SENSOR INSPECTION
[WL-C, WE-C].)
8 INSPECT APP SENSOR NO.1 CIRCUIT FOR Yes Go to the next step.
terminals:
- APP sensor No.1 terminal A (wiring
harness-side)
- APP sensor No.1 terminal B (wiring
harness-side)
connectors.
(Engine off).
(See 01-02B-1 0 AFTER REPAIR No DTC troubleshooting completed.

dcf01 02001 00w17
DTC P0123 Accelerator pedal position (APP) sensor No.1 circuit high input
DETECTION • The PCM monitors the input signal from APP sensor No.1. If the voltage from APP sensor No.1 is more
CONDITION
• APP sensor No.1 malfunction (
CAUSE • Short to power supply in wiring harness between APP sensor No.1 terminal Band PCM terminal 222
• Open circuit in wiring harness between APP sensor No.1 terminal D and PCM terminal 212
• PCM malfunction
01-028-50
APP SENSOR NO.1 PCM
@ (J)
A
@ ® (J)
@ B 222
@ (J)
0
®
APP SENSOR PCM

232 231 230 229 228 22

245 244 243 242 241 24
5 INSPECT APP SENSOR NO.1 SIGNAL CIRCUIT Yes Repair or replace the wiring harness for a possible short to
(Engine off).
• Measure the voltage between APP sensor
ground.
01-028-51

6 INSPECT APP SENSOR NO.1 Yes Replace the APP sensor, then go to Step 9.
• Inspect the APP sensor No.1. No Go to the next step.
[WL-C, WE-C].)
8 INSPECT APP SENSOR NO.1 GROUND Yes Go to the next step.
• Tum the engine switch off. circuit, then go to the next step.
• Inspect for continuity between APP sensor
No.1 terminal D (wiring harness-side) and
connectors.
(Engine off).
• Perform the "After Repair Procedure". (See 01-02B-11 DTC TABLE [WL-C, WE-C).}
OTC P0182 [WL-C, WE-C]

dcf01 02001 00w18
DTC P0182 Fuel temperature sensor circuit low input
DETECTION • The PCM monitors the input signal from the fuel temperature sensor. If the voltage from the fuel
temperature sensor is less than 0.2 V, the PCM determines that there is a malfunction in the fuel
CONDITION
temperature sensor circuit.
• Fuel temperature sensor malfunction
CAUSE • Short to ground in wiring harness between fuel temperature sensor terminal A and PCM terminal 115
• PCM malfunction
01-028-52
DTC P0182 Fuel temperature sensor circuit low input
FUEL TEMPERATURE SENSOR PCM

124 123 122 121 120 119 118 117 116 115 114 113 112 111 110 109 108 107 106 105 104 103 1021
148 147 146 145 144 143 142 141 140 139 138 137 136 135 134 133 132 131 130 129 128 127 1261
172 171 170 169 168 167 166 165 164 163 162 161 160 159 158 157 156 155 154 153 152 151 1501
196 195 194 193 192 191 190 189 188 187 186 185 184 183 182 181 180 179 178 177 176 175 1741
4 INSPECT FUEL TEMPERATURE SENSOR Yes Repair or replace the terminal, then go to Step 8.
• Disconnect the fuel temperature sensor
connector.
5 INSPECT FUEL TEMPERATURE SENSOR Yes Repair or replace the wiring harness for a possible short to
SIGNAL CIRCUIT FOR SHORT TO GROUND ground, then go to Step 8.
connector.
• Inspect for continuity between fuel temperature
sensor terminal A (wiring harness-side) and
body ground.
6 INSPECT FUEL TEMPERATURE SENSOR Yes Replace the fuel temperature sensor, then go to Step 8.
• Inspect the fuel temperature sensor. No Go to the next step.
(See 01-40B-32 FUEL TEMPERATURE
SENSOR INSPECTION [WL-C, WE-C].)
01-028-53

connectors.
(Engine off).
DTC P0183 [WL-C~ WE-C]

dcf01 02001 00w19
DTC P0183 Fuel temperature sensor circuit high input

• The PCM monitors the input signal from the fuel temperature sensor. If the voltage from the fuel
DETECTION
temperature sensor is more than 4.9 V, the PCM determines that there is a malfunction in the fuel
CONDITION
temperature sensor circuit.
• Fuel temperature sensor malfunction
• Open circuit in wiring harness between fuel temperature sensor terminal A and PCM terminal 115
POSSIBLE
• Short to power supply in wiring harness between fuel temperature sensor terminal A and PCM terminal
CAUSE 115 .
• Open circuit in wiring harness between fuel temperature sensor terminal Band PCM terminal 170
• PCM malfunction
@@
A ~----------------~
®
@ (J)
~--~ B ~----------------~

124123122121 120119118117116115114113
1~lQ1~lE1«la1g1~1~1~lA1D
1n1n 1~1~1~1~1~1.lM1~1~1~
1001%lM1~1~1~100lM1M1~1001.
01-028-54
VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to the next step.
4 INSPECT FUEL TEMPERATURE SENSOR Yes Repair or replace the terminal, then go to Step 9.
connector.
5 INSPECT FUEL TEMPERATURE SENSOR Yes Repair or replace the wiring harness for a possible short to
SIGNAL CIRCUIT FOR SHORT TO POWER power supply, then go to Step 9.
SUPPLY No Go to the next step.
(Engine off).
• Measure the voltage between fuel temperature
sensor terminal A (wiring harness-side) and
body ground.
6 INSPECT FUEL TEMPERATURE SENSOR Yes Replace the fuel temperature sensor, then go to Step 9.
• Inspect the fuel temperature sensor. No Go to the next step.
(See 01-408-32 FUEL TEMPERATURE
SENSOR INSPECTION [WL-C, WE-C).}
8 INSPECT FUEL TEMPERATURE SENSOR Yes Go to the next step.
terminals:
- Fuel temperature sensor terminal A (wiring
harness-side)
- Fuel temperature sensor terminal 8 (wiring
harness-side)
01-028-55

connectors.
(Engine off).

dcf01 02001 00w20
DTC P0191 Fuel pressure sensor range/performance malfunction
DETECTION • The PCM monitors the fuel pressure in the common rail via the fuel pressure sensor when the engine
switch is turned to the ON position after the engine has not been run for several hours. If the fuel pressure
CONDITION
is not 0 MPa {O bar, 0 psi}, the PCM determines that there is a fuel pressure sensor malfunction.
POSSIBLE • Fuel pressure sensor malfunction
• Verify related service repair Information • If the vehicle is not repaired, go to the next step.
4 CLASSIFY FUEL PRESSURE SENSOR Yes Go to Step 6.
MALFUNCTION OR PCM MALFUNCTION No Go to the next step.
• Access FRP PID.
(Engine off).
• Monitor the FRP PID.
• Is the FRP PID value 0 MPa {O Bar, 0 psi}
[ECT: below 20 °C{68 OF}]
5 INSPECT FUEL PRESSURE SENSOR Yes Replace the common rail, go to the next step.
01-028-56
Yes Replace the PCM, go to the next step.

(See 01-40B-9 PCM REMOVAUINSTALLATION [WL-C,
connectors.
(Engine off).
7 VE AFTER REPAIR PROCEDURE Yes Go to the applicable inspection.
DTC P0192 Fuel pressure sensor circuit low input

• The PCM monitors the input voltage from the fuel pressure sensor while the engine is running. If the. input
DETECTION
voltage from the fuel pressure sensor is less than 0.2 V, the PCM determines that there is a malfunction in
CONDITION
the fuel pressure sensor circuit.
• Short to ground in wiring harness between fuel pressure sensor terminal C and PCM terminal 109
POSSIBLE
• Open circuit in wiring harness between fuel pressure sensor terminal C and PCM terminal 109
CAUSE
• Short to ground in wiring harness between fuel pressure sensor terminal Band PCM terminal 140
• Fuel pressure sensor signal and ground circuits are shorted each other.
• PCM malfunction
PCM
@
®® ®
@)
@
®CV ®
®
@ CV ® 191
FUEL PRESSURE SENSOR PCM

01-028-57
• Clear the DTC from the PCM memory using (See 01-038-60 INTERMITTENT CONCERN
4 INSPECT FUEL PRESSURE SENSOR Yes Repair or replace the suspected terminal, go to Step 11.
pulled-out terminals, corrosion).
5 INSPECT FUEL PRESSURE SENSOR SIGNAL Yes Repair or replace the wiring harness for a short to ground,
CIRCUIT FOR SHORT TO GROUND go to Step 11.
- Fuel pressure sensor terminal C
- Fuel pressure sensor terminal B
6 INSPECT FUEL PRESSURE SENSOR POWER Yes Repair or replace the wiring harness for an open circuit, go
CIRCUIT FOR OPEN CIRCUIT to Step 11.
• Turn the engine switch to the ON position. No Go to the next step.
(Engine off)
• Inspect the voltage at fuel pressure sensor
terminal C (wiring harness side).
• Is the voltage less than 0.2 V?
7 INSPECT FUEL PRESSURE SENSOR CIRCUIT Yes Repair or replace wiring harness for a short, go to Step 11.
FOR SHORT No Go to the next step.
• Inspect for continuity between fuel pressure
sensor terminals 8 and A.
8 INSPECT FUEL PRESSURE SENSOR Yes Repair the supply pump, go to Step 11.
• Inspect the fuel pressure sensor. (See 01-14B-11 SUPPLY PUMP REMOVAU
(See 01-40B-33 FUEL PRESSURE SENSOR INSTALLATION [WL-C, WE-C].)
INSPECTION [WL-C, WE-C].) No Go to the next step.
9 INSPECT PCM CONNECTOR FOR POOR Yes Repair or replace the suspected terminal, go to Step 11.
10 INSPECT FUEL PRESSURE SENSOR CIRCUIT Yes Repair or replace suspected terminal, go to the next step.
FOR OPEN No Go to the next step.
sensor terminal Band PCM terminal 140.
01-028-58

connectors.
(Engine off).
DTC P0193 Fuel pressure sensor circuit high input

• The PCM monitors the input voltage from the fuel pressure sensor while the engine is running. If the input
DETECTION
voltage from the fuel pressure sensor is more than 4.8 V, the PCM determines that there is a malfunction
CONDITION
in the fuel pressure sensor circuit.
POSSIBLE • Fuel pressure sensor power and signal circuits are shorted to each other.
CAUSE • Short to power supply in wiring between fuel pressure sensor terminal Band PCM terminal 140
• Open circuit in wiring between fuel pressure sensor terminal A and PCM terminal 191
• PCM malfunction
PCM
@ (J)
@ ® (J)
® B
@ ® (J)
FUEL PRESSURE SENSOR PCM

hW
21120119118117116115114113112111110109108107106105
%1«lalG1Ml~I.I.IDl.l~IMl~I.I~IMla
~1~1~1~1~IMl~I~I~I.I~I~I~I~I~IM1M
~1~1~1001~1~IUl~I~IMl~I~I~IM1Nlnln
I~,I
01-028-59
• Connect the current diagnostic tool to the DLC- Perform the "INTERMITIENT CONCERN
4 INSPECT FUEL PRESSURE SENSOR Yes Repair or replace the suspected terminal, go to Step 9.
5 INSPECT FUEL PRESSURE SENSOR SIGNAL Yes Repair or replace harness for short with each other, go to
CIRCUIT FOR SHORT TO POWER SUPPLY Step 9.
(Engine off).
• Measure the voltage between fuel pressure
sensor terminal B (wiring harness-side) and
body ground
• Is the voltage more than 4.8 V
6 INSPECT FUEL PRESSURE SENSOR Yes Repair the supply pump, go to Step 9.
• Inspect the fuel pressure sensor. (See 01-14B-11 SUPPLY PUMP REMOVAU
(See 01-40B-33 FUEL PRESSURE SENSOR INSTALLATION [WL-C, WE-C].)
7 INSPECT PCM CONNECTOR FOR POOR Yes Repair or replace the suspected terminal, go to Step 9.
8 INSPECT FUEL PRESSURE SENSOR FOR Yes Go to the next step.
OPEN CIRCUIT No Repair or replace the wiring harness for an open circuit, go
• Turn the engine switch off. to the next step.
sensor terminal A and PCM terminal 191.
connectors.
(Engine off).
01-028-60
dcf010200200w02
DTC P0201 Fuel injector No.1 circuit open/short

• The PCM monitors each cylinder fuel injector control signal current while the engine is running. If the PCM
DETECTION
detects a control signal current of more or less than the preprogrammed criteria, the PCM determines that
CONDITION
the fuel injector at No.1 cylinder has an open or short circuit.
• Connector or· terminal malfunction
• Fuel injector No.1 malfunction
POSSIBLE • Short to ground in wiring between fuel injector No.1 terminal Band PCM terminal 174
CAUSE • Open circuit in wiring between fuel injector No.1 terminal Band PCM terminal 174
• Open circuit in wiring between fuel injector No.1 terminal A and PCM terminal 125
• PCM malfunction
PCM
FUEL INJECTOR NO.1
®
®
®
®
FUEL INJECTOR NO.1 PCM

• Connect the current diagnostic tool to the DLC- Perform the "INTERMITIENT CONCERN
• Clear the DTC from the PCM memory using _
4 IDENTIFY TRIGGER DTC FOR FREEZE FRAME Yes Go to the next step.
DATA No Go to troubleshooting procedures for the DTC in FREEZE
• Is DTC P0201 on FREEZE FRAME DATA? FRAME DATA.
01-028-61

5 INSPECT FUEL INJECTOR NO.1 CONNECTOR Yes Repair or replace the suspected terminal, then go to Step
FOR POOR CONNECTION 10.
6 INSPECT FUEL INJECTOR ,NO.1 FOR SHORT Yes Repair or replace the wiring harness for a short to ground,
TO GROUND then go to Step 10.
• Disconnect fuel injector No.1 connector.
• Inspect for continuity between the following fuel
injector No.1 connector terminals and body
ground.
- Terminal A (wiring harness-side)
- Terminal 8 (wiring harness-side)
7 INSPECT FUEL INJECTOR NO.1 Yes Replace fuel injector No.1, then go to Step 10.
• Inspect the fuel injector No.1. (See 01-148-15 FUEL INJECTOR REMOVAU
• Is there any malfunction? INSTALLATION [WL-C, WE-C].)
8 INSPECT PCM CONNECTOR FOR POOR Yes Repair or replace the suspected terminal, then go to Step
CONNECTION 10.
9 INSPECT FOR OPEN CIRCUIT BETWEEN FUEL Yes Go to the next step.
INJECTOR NO.1 AND PCM No Repair or replace the wiring harness for an open circuit,
• PCM and fuel injector No.1 connector
disconnected.
• Inspect for continuity between fuel injector No.1
and PCM at following wiring harness-side
connector:
- PCM terminal 174 and fuel injector No.1
terminal 8
<I>
terminal A
COMPLETED (See 01-408-9 PCM REMOVAUINSTALLATION [WL-C,
• Clear the DTC using the current diagnostic
tool.
11 VERIFY AFTER REPAIR PROCEDURE Yes Go to the applicable DTC troubleshooting.
• Perform the "After Repair Procedure". (See 01-028-11 DTC TA8LE [WL-C, WE-C].)
(See 01-028-10 AFTER REPAIR No Troubleshooting completed.

dcf010200200w03
DETECTION • The PCM monitors each cylinder fuel injector control signal current while the engine is running. If the PCM
detects a control signal current of more or less than the preprogrammed criteria, the PCM determine that
CONDITION
POSSIBLE • Short to ground in wiring between fuel injector No.2 terminal 8 and PCM terminal 149
CAUSE • Open circuit in wiring between fuel injector No.2 terminal 8 and PCM terminal 149
• PCM malfunction
01-028-62
PCM
FUEL INJECTOR NO.2
®
®
@
®
~~------~=---------~ 102
®

124123122121 120119118117 116115114113112

1~1Q1.1e1«1g1a1M1~1~1M1~1M
1n1n1ro1~1~1~1~1.1M1~1~1~1M
DATA No Go to the troubleshooting procedures for the DTC in the
• Is DTC P0202 on FREEZE FRAME DATA? FREEZE FRAME DATA.
01-028-63

6 INSPECT FUEL INJECTOR NO.2 FOR SHORT Yes Repair or replace the wiring harness for a short to ground,
injector No.2 terminals and body ground.
- Terminal B (wiring harness-side)
• Inspect the fuel injector No.2. (See 01-14B-15 FUEL INJECTOR REMOVAU
CONNECTION 10.
disconnected.
and PCM at following harness-side connector.
terminal B
terminal A
tool.
PROCEDURE [WL-C, WE-C).}

dcf010200200w04
detects a control signal current of more or less than the preprogrammedcriteria, the PCM determines that
CONDITION
the fuel injector at NO.3 cylinder has an open or short circuit.
• Open circuit in wiring between fuel injector NO.3 terminal A and PCM terminal 101
• peM malfunction
01-028-64
PCM
FUEL INJECTOR NO.3
@
®
®
®
®

148147 146 145 144 143 142 1

172171 170169 168 167 166 1
196195 194193192191 1901
I
\.
• Is DTC P0203 on the FREEZE FRAME DATA? FREEZE FRAME DATA.
01-028-65

injector No.3 terminals and body ground:
CONNECTION 10.
disconnected.
• Inspect for continuity between fuel injector NO.3
and PCM at following wiring harness-side
connector:
terminal B
terminal A
tool.

dcf010200200w05
detects a control signal current of more or less than the preprogrammed criteria, the PCM determines that
CONDITION
• PCM malfunction
01-028-66
PCM
FUEL INJECTOR NO.4
@
®
@
®

lnlnl~I~I~I~IMl~I.I~I~I~I00I.I~I~I~I~IMl
1%1%1~1~1~1~1001~1~IUl~I~IMl~I~I~IOOIMlnl
• Is DTC P0204 on FREEZE FRAME DATA? FREEZE FRAME DATA.
5 INSPECT FUEL INJECTOR NO.4 CONNECTOR Yes Repair or replace the suspected terminal, then ·go to Step
01-028-67

injector No.4 terminals and body ground.
CONNECTION 10.
disconnected.
(wiring harness-side) and PCM at following
wiring harness-side connector.
terminal B
terminal A
tool.
• Perform the "After Repair Procedure". . (See 01-02B-11 DTC TABLE [WL-C, WE-C].)

dcf010200200w06
DETECTION • The PCM monitors the input signal from APP sensor No.2. If the voltage from APP sensor No.2 is less
CONDITION
POSSIBLE • Open circuit in wiring harness between APP sensor No.2 terminal A and PCM terminal 213
CAUSE • Short to ground in wiring harness between APP sensor No.2 terminal A and PCM terminal 213
• Open circuit in wiring harness between APP sensor No.2 terminal C and PCM terminal 209
• Short to ground in wiring harness between APP sensor No.2 terminal C and PCM terminal 209
• PCM malfunction
01-028-68
APP SENSOR NO.2 PCM
@@
@@ ®®
@
@@ @@ CD@
@)@) 209
0
@@ CD@
212
APPSENSOR PCM
108107106105104 103 1
132131 130129128 127 1
1 VERIFY FREEZE FRAME OAT!, HAS BEEN Yes Go to the next step.
(Engine off).
• Measure the voltage between the APP sensor
ground.
OR APP SENSOR RELATED MALFUNCTION No Go to the next step.
(Engine off).
ground.
01-028-69

6 INSPECT APP SENSOR 5V CONSTANT Yes Repair or replace the wiring harness for a possible short to
VOLTAGE CIRCUIT FOR SHORT TO GROUND ground, then go to Step 17.
• Inspect for continuity between the APP sensor
ground
8 INSPECT APP SENSOR 5V CONSTANT Yes Go to step 17.
VOLTAGE CIRCUIT FOR OPEN No Repair or replace the wiring harness for an open circuit,
• Turn the engine switch off. then go to Step 17.
terminal A (wiring harness-side) and PCM
10 INSPECT APP SENSOR Yes Replace the APP sensor, then go to Step 17.
• Inspect the APP sensor. No Go to step 17.
[WL-C, WE-C).)
11 CLASSIFY SIGNAL CIRCUIT OR OTHER Yes Go to Step 13.
,(Engine off).
ground.
• Is the voltage more than 0.29 V ?
12 INSPECT APP SENSOR SIGNAL CIRCUIT FOR Yes Repair or replace the wiring harness for a possible short to
ground
14 INSPECT APP SENSOR SIGNAL CIRCUIT FOR Yes Go to Step 17.
OPEN No Repair or replace the wiring harness for an open circuit,
terminal C (wiring harness-side) and PCM
01-028-70

16 INSPECT APP SENSOR
• Inspect the APP sensor.
[WL-C, WE-Gj.)
• Is there malfunction?
connectors.
(Engine off).
• Perform the "After Repair Procedure". (See 01-02B-11 DTC TABLE [WL-C, WE-Gj.)
• Are DTCs nra,,,ant?

dcf01020020Ow07
DETECTION •
The PCM monitors the input signal from APP sensor No.2. If the voltage from APP sensor No.2 is more
than 4.80 V for 0.5 s when the APP sensor no.2 power supply voltage is normal, the PCM determines that
CONDITION
POSSIBLE • Short to power supply in wiring harness between APP sensor No.2 terminal A and PCM terminal 213
CAUSE • Short to power supply in wiring harness between APP sensor No.2 terminal C and PCM terminal 209
• Open circuit in wiring harness between APP sensor No.2 terminal D and PCM terminal 212
• PCM malfunction
01-028-71
APP SENSOR NO.2 PCM
@@)
~--~ 0 ~--------------~H
APPSENSOR PCM
0ffi0
I~~ I
availabil ity. No Go to the next step.
•Clear the DTC from the PCM memory using (See 01-03B-60 INTERMITTENT CONCERN
(Engine off).
ground.
OR APP SENSOR RELATED MALFUNCTION No Go to the next step.
(Engine off).
ground.
01-028-72
INSPECT PCM CONNECTOR FOR POOR

7 INSPECT APP SENSOR CONNECTOR FOR
POOR CONNECTION
8 PECT APP SENSOR
(See 01-408-28 ACCELERATOR PEDAL
[WL-C, WE-C].)
9 INSPECT APP SENSOR CONNECTOR FOR
10 INSPECT APP SENSOR GROUND CIRCUIT
FOR OPEN CIRCUIT
terminal D and body ground.
CONNECTION Repair or replace the wiring harness for an open circuit,
• Turn the engine switch off. then go to the Step 17.
12 CLASSIFY SIGNAL CIRCUIT OR OTHER
RELATED MALFUNCTION
(Engine off).
ground.
13 CLASSIFY SIGNAL CIRCUIT OR APP SENSOR
RELATED MALFUNCTION
• Turn the engine switch to the ON positioll
(Engine off).
ground.
01-028-73

16 INSPECT APP SENSOR Yes Replace the APP sensor, then go to the step.
• Inspect the APP sensor. No Go to the step.
[WL-C, WE-C].)
COMPLETED (See
01-40B-9 PCM REMOVAUINSTALLATION [WL-C, WE-C].)
connectors.
(Engine off).
PROCEDURE [WL-C, WE-C).)
DTC P0227 [WL-C, WE-C)

dcf01020020Ow08
DTC P0227 Idle switch circuit low input

DETECTION • The PCM monitors the input voltage from APP sensor No.1 when the idle switch is off. If the input voltage is
CONDITION less than 0.86 V for 1.5 s, the PCM determines that the idle switch circuit has a malfunction.
• Idle switch malfunction.
• Accelerator pedal misadjustment.
CAUSE • Open circuit in wiring harness between Idle switch terminal A and PCM terminal 161
• Open circuit in wiring harness between Idle switch terminal B and body ground.
• PCM malfunction
01-028-74
DTC P0227 Idle switch circuit low input
PCM
®
IDELSWITCH -r-
:~
@ ® ~-0---0 ® ® (j)
Q
'7 -
l
IDELSWITCH PCM
CONNECTOR CONNECTOR
124 123 122 121 120 119 118 117 116 115 114 113 112 111 110 109 108 107 106 105 104 103 102 101
148 147 146 145 144 143 142 141 140 139 138 137 136 135 134 133 132 131 130 129 128 127 126 125
172 171 170 169 168 167 166 165 164 163 162 161 160 159 158 157 156 155 154 153 152 151 150 149
196 195 194 193 192 191 190 189 188 187 186 185 184 183 182 181 180 179 178 177 176 175 174 173
1 VERIFY FREEZE FRAME DATA AND Yes Go to the next step.
DIAGNOSTIC MONITORING TEST RESULTS No Record the FREEZE FRAME on the repair order, then go to
HAS BEEN RECORDED the next step.
• Has FREEZE FRAME DATA been recorded?
AVAILABILITY Service information.
• Verify related Service Information availability. If the vehicle is not repaired, go to the next step.
• Is any related Service Information available? No Go to the next step.
4 VERIFY RELATED PENDING CODE OR Yes Go to the next step.
STORED DTC No Go to appropriate DTC troubleshooting procedure.
• Is DTC P0122 present? (See 01-02B-48 DTC P0122 [WL-C, WE-C].)
5 INSPECT IDLE SWITCH CONNECTOR FOR Yes Repair or replace the terminal, then go to Step 10.
• Disconnect the idle switch connector.
6 INSPECT IDLE SWITCH POWER CIRCUIT FOR Yes Go to go to step 8.
OPEN CIRCUIT No Go to the next Step.
(Engine off).
• Measure the voltage between the idle switch
ground.
• Is the voltage B+ ?
01-028-75

7 INSPECT PCM CONNECTOR FOR POOR Yes Repair or replace the terminal, then go to step 10.
CONNECTION No Repair or replace the wiring harness for an open circuit,
pulled-out pins, corrosion)
8 INSPECT IDLE SWITCH GROUND CIRCUIT Yes Go to the next step.
terminal B and body ground.
9 INSPECT IDLE SWITCH Yes Replace the idle switch, then go to the next step.
• Inspect idle switch. (See 01-13B-11 ACCELERATOR PEDAL COMPONENT
(See 01-40B-30 IDLE SWITCH INSPECTION REMOVAUINSTALLATION [WL-C, WE-C].)
[WL-C, WE-C].) No Adjust the accelerator pedal, then go to the next step.
• Is there any malfunction? (See 01-13B-12 ACCELERATOR PEDAL ADJUSTMENT
[WL-C, WE-C].)
connectors.
(Engine off).
(See 01-02B-1 0 AFTER REPAI R No DTC troubleshooting completed.

dcf010200200w09
DTC P0228 Idle switch circuit high input

DETECTION • The PCM monitors the input voltage from APP sensor No.1 when the idle switch is on. If the input voltage is
CONDITION more than 1.35 V for 1.5 s, the PCM determines that the idle switch circuit has a malfunction.
• Idle switch malfunction.
POSSIBLE • Accelerator pedal misadjustment.
CAUSE • Short to ground in wiring harness between idle switch terminal A and PCM terminal 161
• PCM malfunction
r
[ .
01-028-76
DTC P0228 Idle switch circuit high input
PCM
®
IDELSWITCH
--:!::
® 0-0-0-0 ® ® (J)
~
p
l
IDELSWITCH PCM
CONNECTOR CONNECTOR
124123122121 12011911811711611511411
1n1n1ro1~1~1~1001E1M1.1~1~1W1~1~1~1~1~1M1A1.
1001.1M1.1~1~1001~1M1~1001.1M1.1~1~ 1W1m1n1n1n
• Is DTC P0123 present? (See 01-02B-50 DTC P0123 [WL-C, WE-C].)
5 INSPECT IDLE SWITCH CONNECTOR FOR Yes Repair or replace the terminal, then go to Step 9.
• Disconnect the idle switch connector.
6 INSPECT IDLE SWITCH POWER CIRCUIT FOR Yes Go to next the step.
SHORT TO GROUND No Go to Step 8.
• Inspect for continuity between idle switch
terminal A and body ground.
01-028-77

CONNECTION No Repair or replace the wiring harness for a short to ground
• Turn the engine switch off. circuit, then go to Step 9.
(See 01-40B-30 IDLE SWITCH INSPECTION REMOVAUINSTALLATION [WL-C, WE-C].)
[WL-C, WE-C].)
connectors.
(Engine off).
• Perform the "AFTER REPAIR PROCEDURE". (See 01-02B-11 DTC TABLE [WL-C, WE-C].)
• Is any DTC present?

dcf01020030Ow02
DTC P0300 Random misfire detected

• The PCM monitors the CKP sensor input signal interval time. The PCM calculates the deviation of the
interval time for each cylinder. If the deviation of the interval time exceeds the preprogrammed criteria, the
DETECTION PCM detects a misfire in the corresponding cylinder. While the engine is running, the PCM counts the
CONDITION number of misfires and calculates the misfire ratio for each crankshaft revolution. If the ratio exceeds the
preprogrammed criteria, the PCM determines that a misfire, which can affect emission performance, has
occurred.
• Fuel line clogged
• Fuel filter clogged
POSSIBLE • Fuel leakage in fuel line
CAUSE • Fuel run out
• Poor quality fuel
• EGR valve malfunction
• Related connector arid terminal malfunction
• Related wiring harness malfunction
• Insufficient compression
01-028-78
VERIFY FREEZE FRAME DATA AND

DIAGNOSTIC MONITORING TEST RESULTS Record the FREEZE FRAME DATA and DIAGNOSTIC
HAVE BEEN RECORDED MONITORING TEST RESULTS on the repair order, then
• Have FREEZE FRAME DATA and go to the next step.
DIAGNOSTIC MONITORING TEST RESULTS
been recorded?
2 VERI RELATED REPAIR INFORMATION Yes Perform repair or diagnosis according to the available
AVAILABILITY repair information. If the vehicle is not repaired, go to the
• Verify related service repair information next step.
3 VERIFY RELATED PENDING CODE OR Yes Go to appropriate DTC troubleshooting procedure.
STORED DTC (See 01-02B-11 DTC TABLE [WL-C, WE-C].)
• Turn the engine switch off, then ON position No go to the next step.
(Engine off).
• Verify the related PENDING CODE or stored
DTCs using current diagnostic tool.
• Is other DTC present?
4 VERIFY CURRENT INPUT SIGNAL STATUS Yes Inspect the suspected circuit or part or both according to
UNDER TROUBLESHOOTING CONDITION the inspection results.
• Access the BOO, ECT, IAT, MAF, RPM, APp, Then go to Step 12
SEGRP and VSS PIDs using the current No Go to the next step.
diagnostic tool.
• Is any signal that is far out of specification
when the engine switch is at the ON position
and the engine idles?
UNDER TROUBLE CONDITION the inspection results.
• Inspect the same PIDs as in Step 4 while Then go to Step 12
simulating the FREEZE FRAME DATA No Go to the next step.
condition.
• Is there any signal which cause drastic
changes?
6 INSPECT CKP SENSOR
• Inspect the CKP sensor and the pulse wheel.
• Inspect the CMP sensor.
8 INSPECT OPERATION OF EGR VALVE
• Remove the EGR valve.
• Visually inspect if the EGR valve is stuck open.
Is the EGR valve stuck open?
9 INSPECT FUEL LINE Yes Repair or replace the suspected fuel line, then go to Step
• Turn the engine switch off. 12
Inspect the fuel lines for fuel leakage or No go to the next step.
clogging.
10 INSPECT ENGINE COOLANT PASSAGE FOR Yes Repair or replace the malfunctioning part according to the
ENGINE COOLANT LEAKAGE inspection results.
• Perform the engine coolant leakage inspection. f--:-.,.--+T_h_e_n...:g:...o_t_o_S-,-te-'p.,.--12_ _ _ _ _ _ _ _ _ _ _ _ _-l
Is there any malfunction?
11 INSPECT ENGINE COMPRESSION
• Inspect the engine compression for the
suspected cylinder.
Is the engine compression normal?
12 VERIFY TROUBLESHOOTING OF MISFIRE DTC Yes Replace PCM, then go to the next step.
• Make sure to reconnect all disconnected WE-C).)
connectors. No go to the next step.
01-028-79

• Perform "After Repair Procedure". (See 01-02B-11 DTC TABLE [WL-C, WE-C].)
PROCEDURE [WL-C, WE-Gj.)
DTC P0301, P0302, P0303, P0304 [WL-C, WE-C]

dcf010200300w03
DTC P0301
Cylinder No.1 misfire detection
DTC Cylinder No.2 misfire detection
P0302
DTC Cylinder No.3 misfire detection
P0303
DTC P0304
Cylinder No.4 misfire detection
• The PCM monitors the CKP sensor input signal interval time. The PCM calculates the deviation of the
interval time for each cylinder. If the deviation of the interval time exceeds the preprogrammed criteria, the
DETECTION PCM detects a misfire in the corresponding cylinder. While the engine is running, the PCM counts the
CONDITION number of misfires and calculates the misfire ratio for each crankshaft revolution. If the ratio exceeds the
preprogrammed criteria, the PCM determines that a misfire, which can affect emission performance, has
occurred.
• Fuel injector malfunction
POSSIBLE • CMP sensor malfunction
CAUSE • Inadequate engine compression due to engine internal malfunction
• Related connector or terminal malfunction
DATA No Go to troubleshooting procedures for the DTC on the
• Is DTC P0301, P0302, P0303 or P0304 on FREEZE FRAME DATA.
FREEZE FRAME DATA?
5 INSPECT FUEL LINE Yes Repair or replace the suspected fuel line, then go to Step
• Turn the engine switch off. 13.
• Inspect the fuel lines of the suspected cylinder No Go to the next step.
for fuel leakage or clogging.
UNDER TROUBLESHOOTING CONDITION the inspection results.
• Access the BOO, ECT, IAT, MAF, RPM, APP, Then go to Step 13.
SEGRP and VSS PIDs using the current No Go to the next step.
diagnostic tool.
• Is any signal that is far out of specification
when the engine switch is at the ON position
and the engine idles?
(
01-028-80

7 VERIFY CURRENT INPUT SIGNAL STATUS Yes Inspect suspected circuit or part or both according to the
UNDER TROUBLE CONDITION inspection results.
• Inspect the same PIDs as in Step 6 while Then go to Step 13.
simulating the FREEZE FRAME DATA No Go to the next step.
condition.
• Is there any signal which cause drastic
changes?
8 INSPECT CKP SENSOR Yes Repair or replace the suspected part according to the
• Inspect the CKP sensor and the pulse wheel. inspection results, then go to Step 13.
• Is there any malfunction? No Go to the next step.
9 INSPECT CMP SENSOR Yes Repair or replace the suspected part according to the
• Inspect the CMP sensor. inspection results, then go to Step 13.
10 INSPECT ENGINE COOLANT PASSAGE FOR Yes Repair or replace the malfunctioning part according to the
ENGINE COOLANT LEAKAGE inspection results.
Then go to Step 13.
• Perform the engine coolant leakage inspection.
11 INSPECT ENGINE COMPRESSION Yes Go to the next step.
• Inspect the engine compression for the No Overhaul the engine, then go to Step 13.
suspected cylinder.
• Is the engine compression normal?
12 INSPECT FUEL INJECTOR Yes Repair or replace the suspected part according to the
• Inspect the fuel injector and the related circuit inspection results, then go to the next step.
for the suspected cylinder. No Go to the next step.
13 VERIFY TROUBLESHOOTING OF MISFIRE DTC Yes Replace the PCM, then go to the next step.
WE-C].)
• Access the ECT PID using the current
diagnostic tool.
• Warm-up the engine until the ECT PID is above
40°C {104 OF}.
• Idle engine for 5s or more.
• Repeat the above mentioned for twice.
• .Is the same DTC present?
(See 01-02B-10 AFTER REPAIR No Troubleshooti ng completed.

dcf01020030Ow04
DTC P0335 Crankshaft position (CKP) sensor circuit malfunction

• The PCM monitors the input signal from the CKP sensor while the engine is running. If the following
DETECTION conditions are detected, the PCM determines that the CKP circuit has a malfunction.
CONDITION - The PCM receives no pulse from the CKP sensor
- The PCM receives an improper pulse number from the CKP sensor
• Short to power supply between CKP sensor terminal Band PCM terminal 193
• Short to power supply between CKP sensor terminal A and PCM terminal 192
POSSIBLE • Short to ground between CKP sensor terminal C and PCM terminal 194
CAUSE • Short to ground between CKP sensor terminal Band PCM terminal 193
• Open circuit between CKP sensor terminal Band PCM terminal 193
• Open circuit between CKP sensor terminal A and PCM terminal 192
• Loose CKP sensor installation bole
• CKP sensor pulse wheel malfunction
• PCM malfunction
01-028-81
DTC P0335 I Crankshaft position (CKP) sensor circuit malfunction
PCM
CKP SENSOR
,, -..- .......................... ';" ..,,
·
,, \., ®®® ,/
,,
@
B
(j) ,
@r:--
"" ,, .. , ,,
.
,, //
~ D (j)
'"
·.··
,
··· .
, ,
,
j®®®~ , . .
B
, @
0s
\.J
"
"
, ,
.... --------------- , ,
-//
'"
8
(j)
~/
CS "" '"
CKP SENSOR WIRING HARNESS-SIDE PCM WIRING HARNESS-SIDE

CONNECTOR CONNECTOR
6lfBID
124 123 122 121 120 119 118 117 116 115 114 113 112 111 110 109 108 107 106 105 104 103 102 101
148 147 146 145 144 143 142 141 140 139 138 137 136 135 134 133 132 131 130 129 128 127 126 125
172 171 170 169 168 167 166 165 164 163 162 161 160 159 158 157 156 155 154 153 152 151 150 149
196 195 194 193 192 191 190 189 188 187 186 185 184 183 182 181 180 179 178 177 176 175 174 173
I~~ I I~~ I
RECORDED No Record FREEZE FRAME DATA on repair order, then go to
• Has the FREEZE FRAME DATA been the next step.
recorded?
2 VERIFY RELATED REPAIR INFORMATION Yes Perform repair or diagnosis according to available repair
AVAILABILITY information.
• Verity related service repair information • If vehicle is not repaired, go to the next step.
4 INSPECT CKP CIRCUIT FOR SHORT TO Yes Repair or replace the wiring harness, then go to Step 12.
POWER SUPPLY No Go to the next step.
• Disconnect the CKP sensor connector.
• Turn the engine switch to the ON position.
(Engine off).
• Measure the voltage between the following ,
terminals (wiring harness-side):
- CKP sensor terminal A and body ground
- CKP sensor terminal B and body ground
01-028-82

5 VERIFY CKP SENSOR INSTALLATION Yes Retighten the CKP sensor installation bolt, then go to Step
CONDITION 12.
• Inspect for CKP sensor looseness. (See 01-408-38 CRANKSHAFT POSITION (CKP)
• Is CKP sensor loosen? SENSOR REMOVAUINSTALLATION [WL-C, WE-C].)
6 INSPECT CKP SENSOR Yes Go to the next step.
• Turn the engine switch off. No Replace the CKP sensor, then go to Step 12.
• Inspect the CKP sensor. (See 01-408-38 CRANKSHAFT POSITION (CKP)
(See 01-408-39 CRANKSHAFT POSITION SENSOR REMOVAUINSTALLATION [WL-C, WE-C].)
(CKP) SENSOR INSPECTION [WL-C, WE-C].)
• Is the CKP sensor normal?
7 INSPECT CKP SENSOR CONNECTOR FOR Yes Go to the next step.
POOR CONNECTION No Reconnect the connector, then go to Step 12.
• Verify that the CKP sensor connector is
connected securely.
• Is the connector normal?
8 INSPECT CKP CIRCUIT FOR SHORT TO Yes Repair or replace the wiring harness, then go to Step 12.
GROUND No Go to the next step.
• Inspect for continuity the between the following
terminals:
- CKP sensor connector terminal A (wiring
- CKP sensor connector terminal 8 (wiring
9 INSPECT CKP CIRCUIT FOR OPEN CIRCUIT Yes Go to the next step.
• Turn the engine switch off. No Repair or replace the wiring harness, then go to Step 12.
terminals:
- CKP sensor terminal A (wiring harness-
harness-side)
- CKP sensor terminal 8 (wiring harness-
harness-side)
10 INSPECT DUAL-MASS FLYWHEEL Yes Replace the dual-mass flywheel, then go to Step 12.
• Inspect the dual-mass flywheel for damage (See 05-10-12 CLUTCH UNIT REMOVAUINSTALLATION.)
and/or cracks. No Go to the next step.
11 INSPECT PCM CONNECTOR FOR POOR Yes Repair the terminal, then go to the next step.
IS COMPLETED (See 01-408-9 PCM REMOVAUINSTALLATION [WL-C,
connectors.
(Engine off).
01-028-83


dcf010200300wOS
DTC P0340 Camshaft position (CMP) sensor circuit malfunction

• The PCM monitors the input signal from the CMP sensor while the engine is running. If the following
DETECTION conditions are detected, the PCM determines that the CMP circuit has a malfunction.
CONDITION - The PCM receives no pulse from the CMP sensor
- The PCM receives an improper pulse number from the CMP sensor
• Short to power supply between CMP sensor terminal C and PCM terminal 129
• Short to power supply between CMP sensor terminal Band PCM terminal 160
• Short to power supply between CMP sensor terminal A and PCM terminal 114
• Short to ground between CMP sensor terminal C and PCM terminal 129
POSSIBLE
• Short to ground between CM P sensor terminal Band PCM terminal 160
CAUSE
• Open circuit between CMP sensor terminal C and PCM terminal 129
• Open circuit between CMP sensor terminal Band PCM terminal 160
• Open circuit between CMP sensor terminal A and PCM terminal 114
• Loose CMP sensor installation bolt
• CMP sensor pulse wheel malfunction
• PCM malfunction
PCM
CMP
®@®
®@®
®®
CMP SENSOR WIRING HARNESS-SIDE PCM WIRING HARNESS-SIDE

CONNECTOR CONNECTOR
01-028-84
VERIFY FREEZE FRAME DATA HAS BEEN

RECORDED
• Has the FREEZE FRAME DATA been
recorded?
• Verify related service repair information • If vehicle is not repaired, go to the next step.
• Is any related information available?
3 VERIFY CURRENT SIGNAL STATUS: IS
CONCERN INTERMITTENT OR CONSTANT? Intermittent concern exists.
• Connect the current diagnostic tool to the DLC- Perform the "INTERMllTENT CONCERNS
• Clear the DTC from the PCM memory using (See 01-03B-60 INTERMllTENT CONCERN
4 INSPECT CMP CIRCUIT FOR SHORT TO
POWER SUPPLY
(Engine off).
• Measure the voltage between the following
- CMP sensor terminal A and body ground
- CMP sensor terminal B and body ground
- CMP sensor terminal C and body ground
5 VERIFY CMP SENSOR INSTALLATION Yes Retighten the CMP sensor installation bolt, then go the
CONDITION Step 12.
• Inspect for CMP sensor looseness. (See 01-40B-36 CAMSHAFT POSITION (CMP) SENSOR
• Is CMP sensor loosen? REMOVAUINSTALLATION [WL-C, WE-C].)

• Turn the engine switch off. Replace the CMP sensor, then go to Step 12.
• Inspect the CMP sensor. (See 01-40B-38 CRANKSHAFT POSITION (CKP)
(See 01-40B-37 CAMSHAFT POSITION SENSOR REMOVAUINSTALLATION [WL-C, WE-C].)
C).)
• Is the CMP sensor normal?
7 INSPECT CMP SENSOR CONNECTOR FOR
POOR CONNECTION
• Verify that the CMP sensor connector is
connected securely.
• Is the connector normal?
8 CMP CIRCUIT FOR SHORT TO
GROUND
• Inspect for continuity the between the following
terminals:
- CMP sensor connector terminal C (wiring
- CMP sensor connector terminal B (wiring
01-028-85

9 INSPECT CMP CIRCUIT FOR OPEN CIRCUIT Yes Go to Step the next step.
• Turn the engine switch off. No Repair or replace the wiring harness, then go to Step 12.
terminals:
- CMP sensor terminal C (wiring harness-
harness-side)
- CMP sensor terminal 8 (wiring harness-
harness-side)
- CMP sensor terminal A (wiring harness-
harness-side)
10 INSPECT CMP SENSOR PULSE WHEEL Yes Replace the camshaft pulley, then go to Step 12.
• Inspect the CMP sensor pulse wheel for (See 01-108-9 CYLINDER HEAD GASKET
damage and/or cracks. REPLACEMENT [WL-C, WE-C].)
• Is there any malfunction? No Go to the riext step.
IS COMPLETED (See 01-408-9 PCM REMOVAUINSTALLATION [WL-C,
connectors.
(Engine off).
(See 01-028-10 AFTER REPAIR No DTC troubleshooting completed.

dcf010200300w06
DTC P0380 Glow plug relay circuit malfunction

• The PCM monitors the glow plug relay control signal. If the following conditions are detected, the PCM
determines that the glow plug relay circuit has a malfunction.
DETECTION
- The PCM turns the glow plug relay off but the voltage remains low
CONDITION
- The PCM turns the glow plug relay on but the voltage remains high
- The PCM internal driver IC temperature is more than 150 °C {320 OF} when the glow plug relay is on
• Glow plug relay malfunction
• Glow plug malfunction
• Open circuit in wiring harness between glow plug relay terminal 2A and battery
• Open circuit in wiring harness between glow plug relay terminal 18 and main relay
• Open circuit in wiring harness between glow plug relay terminal1A and PCM terminal 182
POSSIBLE • Open circuit in wiring harness between glow plug relay terminal3A and PCM terminal 227
CAUSE • Open circuit in wiring harness between glow plug relay terminal 3A and glow plug terminals
• Short to ground circuit in wiring harness between glow plug relay terminal 1A and PCM terminal 182
• Short to ground circuit in wiring harness between glow plug relay terminal 3A and glow plug terminals
• Short to power supply between glow plug relay terminal 1A and PCM terminal 182
• Short to power supply between glow plug relay terminal 3A and PCM terminal 227
• PCM malfunction
01-028-86
DTC P0380 Glow plug relay circuit malfunction
MAIN RELAY
GLOW PLUG RELAY PCM
@@
GLOW PLUG
GLOW PLUG WIRING GLOW PLUG RELAY PCM WIRING HARNESS-SIDE

HARNESS-SIDE WIRING HARNESS-SIDE CONNECTOR
CONNECTOR CONNECTOR
r1Al 218217216215214213212211210209208207
231 230 229 228 227 226 225 224 223 222 221 220
@ 244 243 242 241 240 239 238 237 236 235 234 233
257 256 255 254 253 252 251 250 249 248 247 246
recorded?
4 INSPECT GLOW PLUG RELAY CONNECTOR Yes Repair or replace the terminal, then go to Step 15.
• Disconnect the glow plug relay connector.
01-028-87

5 INSPECT GLOW PLUG RELAY POWER SUPPLY Yes Go to the next step.
• Measure the voltage between glow plug relay
terminal 18 and body ground.
terminal2A and body ground.
6 INSPECT GLOW PLUG RELAY Yes Go to the next step.
• Inspect the glow plug relay. No Replace the glow plug, then go to Step 15.
7 INSPECT GLOW PLUG CONNECTOR FOR Yes Repair or replace the suspected terminal, then go to Step
POOR CONNECTION 15.
8 INSPECT GLOW PLUG RELAY CIRCUIT FOR Yes Repair or replace the wiring harness for a short to ground,
SHORT TO GROUND then go to Step 15.
• Inspect for continuity between glow plug relay
terminal 3A and ground.
9 INSPECT GLOW PLUG RELAY CIRCUIT FOR Yes Go to the next step
OPEN CIRCUIT No Repair or replace the wiring harness for an open circuit,
terminals and glow plug terminals.
10 INSPECT GLOW PLUG Yes Go to the next step.
• Inspect the glow plug. No Replace the glow plug, then go to Step 15.
(See 01-138-9 GLOW PLUG INSPECTION
[WL-C, WE-C].)
CONNECTION 15.
12 INSPECT GLOW PLUG RELAY CIRCUIT FOR Yes Repair or replace the wiring harness for a short to ground,
terminal1A and body ground.
13 INSPECT GLOW PLUG RELAY CIRCUIT FOR Yes Repair or replace the wiring harness for a short to power
SHORT TO POWER SUPPLY supply, go to Step 15.
• Disconnect the glow plug relay connector and No Go to the next step.
PCM connector.
(Engine off.)
• Inspected the voltage between the following
- Glow plug relay terminal 1A (wiring harness-
side) and body ground.
- Glow plug relay terminal 3A (wiring harness-
• Is the voltage B+
01-028-88
Repair or replace the wiring harness for an open circuit,

terminals:
- Glow plug relay terminal1A and PCM
terminal 182
- Glow plug relay terminal 3A and PCM
terminal 227
connectors.
(Engine off).
• Are any DTCs nrc'"cnt',

dcf01020040Ow02
DTC P0403 EGR solenoid valve circuit malfunction

• The PCM monitors the EGR solenoid valve control signal. If the following conditions are detected, the PCM
determines that the EGR solenoid valve circuit has a malfunction (open circuit).
DETECTION
- The PCM turns the EGR solenoid valve off but the voltage remains low
CONDITION
- The PCM internal driver IC temperature is more than 150°C {320 OF} when the EGR solenoid valve is
on
• EGR solenoid valve malfunction
POSSIBLE
• Open circuit in wiring harness between main relay and EGR solenoid valve terminal A
CAUSE
• Open circuit in wiring harness between EGR solenoid valve terminal Band PCM terminal 176
• PCM malfunction
EGR SOLENOID VALVE PCM

MAIN RELAY
® ~r*p___ @_8_ _ _(f)*,. ~

lWl~I~IWl~IMl~I~I~I00I~I~I~I~I~IMlg
1.1.1~1~1~IWl~IW1U1Ml~I.I~I00lnlnln
01-028-89
• Has FREEZE FRAME DATA been recorded? the next step.
availability? No Go to the next step.
4 INSPECT EGR SOLENOID VALVE CONNECTOR Yes Repair or replace terminal, then go to Step 9.
• Disconnect the EGR solenoid valve connector.
pulled-out pins, and corrosion).
5 INSPECT EGR SOLENOID VALVE CONTROL Yes Go to the next step.
(Engine off).
• Measure the voltage between EGR solenoid
body ground.
6 INSPECT EGR SOLENOID VALVE Yes Go to the next step.
• Inspect the EGR solenoid valve. No Replace the EGR solenoid valve, then go to Step 9.
(See 01-16B-5 EGR SOLENOID VALVE (See 01-16B-4 EGR SYSTEM REMOVAUINSTALLATION
INSPECTION [WL-C, WE-C].) [WL-C, WE-C].)
• Is the EGR solenoid valve normal?
7 INSPECT PCM CONNECTOR FOR POOR Yes Repair or replace terminal, then go to the next step.
8 INSPECT EGR SOLENOID VALVE CONTROL Yes Go to the next step.
• Inspect for continuity between EGR solenoid
WE-C].)
connectors.
(Engine off).
• Retrieve DTCs using the current diagnostic
tool.
01-028-90

DTC P0405EGR valve position sensor circuit low input

• The PCM monitors the input voltage from the EGR valve position sensor while the engine is running. If the
DETECTION
input voltage is less than 0.1 V, the PCM determines that the EGR valve position sensor circuit has a
CONDITION
malfunction.
• EGR valve position sensor malfunction
• Short to ground circuit between EGR valve position sensor terminal C and PCM terminal 116.
POSSIBLE
• Short to ground circuit between EGR valve position sensor terminal Band PCM terminal 116.
CAUSE
• Open circuit between EGR valve position sensor terminal C and PCM terminal 116.
• Open circuit between EGR valve position sensor terminal Band PCM terminal 106.
• PCM malfunction
EGRVALVE
PCM
POSITION SENSOR
@ @@ (j)
@ @@ (j)
®
@ (j)
A
EGR VALVE POSITION SENSOR PCM

®
I~~ I
• Has FREEZE FRAME DATA been recorded? then go to the next step .
• Check for related service repair information • If the vehicle is not repaired, go to the next step.
01-028-91

• Connect the current diagnostic tool to the DLC- Perform the "INTERMITIENT CONCERNS
• Clear the DTC from the PCM memory using (See 01-03B-60 INTERMITIENT CONCERN
4 INSPECT EGR VALVE POSITION SENSOR Yes Repair or replace the terminal, then go to Step9.
• Disconnect the EGR valve position sensor
connector.
5 INSPECT EGR VALVE POSITION SENSOR Yes Repair or replace the wiring harness for a possible short to
CIRCUIT FOR SHORT TO GROUND ground, then go to Step 9.
terminals:
- EGR valve position sensor terminal B
(wiring harness-side) and body ground
- EGR valve position sensor terminal C
(wiring harness-side) and body ground
• Is the EGR valve position sensor normal?
6 INSPECT EGR VALVE POSITION SENSOR Yes Replace the EGR valve, then go to Step 9.
• Inspect the EGR valve position sensor. (See 01-16B-4 EGR SYSTEM REMOVAUINSTALLATION
(See 01-40B-40 EGR VALVE POSITION [WL-C, WE-C].)
SENSOR INSPECTION [WL-C, WE-C].) No Go to the next step.
7 INSPECT PCM CONNECTOR FOR POOR Yes Repair or replace the terminal, then go to step9.
8 INSPECT EGR VALVE POSITION SENSOR Yes Go to the next step.
- EGR valve position sensor terminal B
(wiring harness-side) and PCM terminal 106
(wiring harness-side)
- EGR valve position sensor terminal C
(wiring harness-side) and PCM terminal 116
9 VERIFY TROUBLESHOOTING OF DTC P040S Yes Replace the PCM, then go to the next step.
WE-C].)
connectors.
(Engine off).
01-028-92

dcf010200400w04
DTC P0406 EGR valve position sensor circuit high input

• The PCM monitors the input voltage from the EGR valve position sensor while the engine is running. If the
DETECTION
input voltage is more than 4.9 V, the PCM determines that the EGR valve position sensor circuit has a
CONDITION
malfunction.
• EGR valve position sensor malfunction
CAUSE • Open circuit between EGR valve position sensor terminal A and PCM terminal 110
• Short to constant voltage supply between EGR valve position sensor terminal C and PCM terminal 116
EGRVALVE
PCM
POSITION SENSOR
@@ @) ®
B
@@ CV@) ®
®
@@ @ ®
A
EGR VALVE POSITION SENSOR PCM

~
124 123 122 121 120 119 118 117 116 115 114 113 112 111 110 109 108 107 106 105 104 103 102 101
148 147 146 145 144 143 142 141 140 139 138 137 136 135 134 133 132 131 130 129 128 127 126 125
172 171 170 169 168 167 166 165 164 163 162 161 160 159 158 157 156 155 154 153 152 151 150 149
196 195 194 193 192 191 190 189 188 187 186 185 184 183 182 181 180 179 178 177 176 175 174 173
I~~ I
• Check for related service repair information • If the vehicle is not repaired, go to the next step.
CONNECTOR No Connect the connector securely, then go to Step 11.
• Turn the engine switch to off.
• Verify that the EGR valve position sensor
connector is connected securely.
• Is connector normal?
01-028-93

5 INSPECT EGR VALVE POSITION SENSOR Yes Repair or replace suspected terminal, then go to Step 11.
• Disconnect the EGR valve position sensor
connector.
• Inspect for poor connection (such as damaged,
• Perform EGR valve position sensor inspection. No Replace the EGR valve position sensor, then go to Step 11.
(See 01-40B-40 EGR VALVE POSITION (See 01-16B-4 EGR SYSTEM REMOVAUINSTALLATION
SENSOR INSPECTION [WL-C, WE-C].) [WL-C, WE-C].)
• Is the EGR valve position sensor normal?
7 INSPECT EGR VALVE POSITION SENSOR Yes Repair or replace for short to power supply, then go to Step
SIGNAL FOR SHORT TO POWER SUPPLY 11.
• Turn the engine switch to ON (engine off). No Go to the next step.
• Measure voltage between EGR valve position
ground.
• Is voltage more than 4.9V?
8 VERIFY EGR VALVE POSITION SENSOR Yes Go to the next step.
GROUND CIRCUIT FOR OPEN CIRCUIT No Repair or replace for open circuit.
• inspect for continuity at wiring harness-side Then go to Step 11.
connector between EGR valve position sensor
terminal A and PCM terminal 110.
• Is there any continuity?
9 INSPECT PCM CONNECTORS FOR POOR Yes Repair or replace terminal, then go to Step 11.
10 VERIFY EGR POSITION SIGNAL CIRCUIT FOR Yes Repair or replace for short circuit, then go to the next step.
SHORT TO CONSTANT VOLTAGE CIRCUIT No Go to the next step.
• inspect for continuity at EGR valve position
sensor wiring harness side connector between
terminal Band C.
WE-C].)
connectors.
(Engine off).
01-028-94
dcf010200400w05
DTC P0489 EGR solenoid valve control circuit low input

• The PCM monitors the EGR solenoid valve control signal. If the PCM turns the EGR solenoid valve off but
DETECTION
the voltage remains low, the PCM determines that EGR solenoid valve circuit has a malfunction (circuit
CONDITION
short to ground).
POSSIBLE • Short to ground in wiring harness between EGR solenoid valve terminal Band PCM terminal 176
CAUSE • Connector or terminal malfunction
• PCM malfunction
®
~§
'--------~

124123122121120119118117116115114113112111110 1091081071061
19lQl%lgl«lalalMl~1.1.lTI1.1U1Ml~1~1~lWl
lnln lrolWl~l~l~l~lMl~l~l~lMl~l~l~l~l~lMl
l%l%lMl~l~l~l~l~l~l~l~l~lMl~l~lMl~l~lnl
. DATA stored condition .
4 INSPECT EGRSOLENOID VALVE CONNECTOR Yes Repair or replace the terminal, then go to Step 8.
• Inspect for poor connection (damaged/pulled-
out pins, corrosion, etc.).
MALFUNCTION No Replace the EGR solenoid valve, then go to step 8.
• Perform EGR solenoid valve inspection.
(See 01-16B-5 EGR SOLENOID VALVE
• Is EGR solenoid valve normal?
01-028-95

6 INSPECT EGR SOLENOID VALVE CONTROL Yes Repair or replace the wiring harness for short to ground,
CIRCUIT FOR SHORT TO GROUND then go to Step 9.
• Disconnect the EGR solenoid valve connector
and PCM connector.
• Inspect for continuity between EGR solenoid
body ground.
• Inspect for poor connection at terminal 176.
(damaged/pulled-out pins, corrosion, etc.).
connectors.
(Engine off).
tool.
• Are any DTC present?

dcf010200400w06
DTC P0490 EGR solenoid valve control circuit high input
DETECTION • The PCM monitors the EGR solenoid valve control signal. If the PCM turns the EGR solenoid valve on but
the voltage remains high, the PCM determines that EGR solenoid valve circuit has a malfunction (circuit
CONDITION
short to power supply).
POSSIBLE • Short to power supply in wiring harness between EGR solenoid valve terminal Band PCM terminal 176
- CAUSE • Connector or terminal malfunction
• PCM malfunction
01-028-96
DTC P0490 EGR solenoid valve control circuit high input
MAIN RELAY PCM
EGR SOLENOID VALVE

@ @ (J)'@

1 VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to the next step,
CONCERN INTERMITTENT OR CONSTANT? ,. No Intermittent concern exists.
4 INSPECT EGR SOLENOID VALVE CONNECTOR Yes Repair or replace the terminal, then go to Step 8.
MALFUNCTION No Replace the EGR solenoid valve, then go to Step 8.
• Perform EGR solenoid valve inspection.
(See 01-16B-5 EGR SOLENOID VALVE
INSPECTION [WL-C, WE-C).)
• Is the EGR solenoid valve normal?
6 INSPECT PCM CONNECTOR FOR POOR Yes Repair the terminal, then go to Step 8.
(such as damaged/pulled-out pins, corrosion).
01-028-97

7 INSPECT EGR SOLENOID VALVE CONTROL Yes Repair or replace the wiring harness for short to power
CIRCUIT SHORT TO POWER SUPPLY supply, then go to the next step.
(Engine off).
• Measure the voltage between EGR solenoid
body ground.
connectors.
(Engine off).
tool.
DTC POSOO [WL-C, WE-C]

dcf01020050Ow03
DTC P0500 VSS circuit malfunction

DETECTION • The PCM monitors the input signal from the instrument cluster during set conditions. If the input signal is
CONDITION less than 0 km/h {O mph} for 25 s, the PCM determines that there is a VSS circuit malfunction.
• PCM malfunction
POSSIBLE
• Instrument cluster malfunction
CAUSE
• Open circuit in wiring harness between PCM terminal 184 and instrument cluster terminal 2F
• Short to ground in wiring harness between PCM terminal 184 and instrument cluster terminal 2F
INSTRUMENT CLUSTER PCM
®cv@ @
INSTRUMENT CLUSTER PCM

01-028-98
RECORDED No Record the FREEZE FRAME PID DATA on the repair order,
• Has FREEZE FRAME PID DATA been then go to the next step.
recorded?
AVAILABILITY service repair Information.
• Verify related service repair Information • If the vehicle is not repaired, go to the next step.
3 VERIFY CURRENT INPUT SIGNAL STATUS: IS Yes Intermittent concern exists.
CONCERN INTERMITTENT OR CONSTANT Perform the "INTERMITTENT CONCERNS
• Connect the current diagnostic tool to the DLC- TROUBLESHOOTING".
2. (See 01-03B-60 INTERMITTENT CONCERN
• Start engine. TROUBLESHOOTING [WL-C, WE-C].)
• Access VSS PID. No Go to the next step.
• Read the VSS PID when the vehicle is driving.
• Is the VSS PID normal?
4 CHECK INPUT/OUTPUT CHECK MODE Yes DTC 10 and/or 12 displayed: Inspect instrument cluster.
• Turn the ignition switch to the ON position (See 09-22-4 INSTRUMENT CLUSTER INPUT/OUTPUT
(Engine off). CHECK MODE.)
• Is instrument cluster DTCs 10 or 12 detected? No Go to the next step.
(See 09-22-4 INSTRUMENT CLUSTER
INPUT/OUTPUT CHECK MODE.)
5 INSPECT INSTRUMENT CLUSTER Yes Go to the next step.
CONNECTOR FOR POOR CONNECTION No Repair or replace terminals, then go to Step 10.
• Turn the ignition switch off.
• Disconnect instrument cluster connector.
• Inspect for poor connections (damaged/pulled-
out terminals, corrosion, etc.).
• Are terminals normal?
6 INSPECT VOLTAGE Yes Replace instrument cluster, then go to Step 10.
• Turn the ignition switch to the ON position (See 09-22-2 INSTRUMENT CLUSTER REMOVAU
(Engine off). INSTALLATION.)
• Measure voltage at instrument cluster terminal No Go to the next step.
2F (wiring harness-side).
• Is there 5 V at instrument cluster terminal 2F
(wiring harness-side)?
7 INSPECT VSS CIRCUIT FOR SHORT TO Yes Repair or replace harness, then go to Step 10.
• Inspect for continuity between instrument
cluster terminal 2F (wiring harness-side) and
body ground.
8 INSPECT PCM CONNECTOR FOR POOR Yes Go to the next step.
CONNECTION No Repair or replace pin or connector, then go to Step 10.
• Disconnect PCM connector.
• Are terminals normal?
9 INSPECT VSS CIRCUIT FOR OPEN CIRCUIT Yes Replace instrument cluster then go to the next step.
• Turn the ignition switch off. No Repair or replace harness, then go to the next step.
• Turn the ignition switch to the ON position
(Engine off).
• Inspect for continuity between instrument
cluster terminal 2F (wiring harness-side) and
01-028-99

10 VERIFY TROUBLESHOOTING OF DTC P0500 Yes Replace PCM, then go to the next step.
WE-C].)
connectors.
(Engine off).
tool.

dcf010200500w04
DTC P0563 Battery voltage high input

DETECTION • The PCM monitors the battery voltage. If the battery voltage is more than 16 V, the PCM determines that
CONDITION there is a malfunction in the battery charging system.
• Generator malfunction
• Battery malfunction
CAUSE • Open circuit in wiring harness between generator terminal S and battery positive terminal
• PCM malfunction
GENERATOR PCM
S @ ®
B @ ENGINE
SWITCH
BATTERY
GENERATOR PCM
01-028-100
"n,.. ",1',',. nrnt"Ot'lure
VERIFY FREEZE FRAME DATA HAS BEEN

RECORDED
a Has FREEZE FRAME DATA been recorded?
a Verify related service repair information a If the vehicle is not repaired, go to the next step.
a Is any related repair information available?
CONCERN INTERMITTENT OR CONSTANT? Intermittent concern exists.
a Connect the current diagnostic tool to the DLC- Perform the "INTERMITTENT CONCERN
a Clear the DTC from the PCM memory using (See 01-03B-60 INTERMITTENT CONCERN
a Start the engine.
a Is the same DTC nro·c>ont·,
4 INSPECT GENERATOR TERMINAL FOR POOR

INSTALLATION
a Turn the engine switch off.
a Inspect generator terminal B for looseness.
a Is there any malfunction?
5 INSPECT GENERATOR Yes Replace the generator, then go to Step 10.
a Inspect the generator. (See 01-17-4 GENERATOR REMOVAUINSTALLATION.)
(See 01-17-5 GENERATOR INSPECTION.) No Go to the next step.
6 INSPECT BATTERY POSITIVE TERMINAL FOR Yes Connect the battery positive terminal correctly, then go to
POOR INSTALLATION Step 10.
a Turn the engine switch off. No Go to the next step.
• Inspect the battery positive terminal for
looseness.
7 INSPECT BATTERY Yes Replace the battery, then go to Step 10.
• Inspect the battery. (See 01-17-2 BATTERY REMOVAUINSTALLATION.)
(See 01-17-2 BATTERY INSPECTION.) No Go to the next step.
CONNECTION
9 INSPECT GENERATOR CIRCUIT SHORT
CIRCUIT Repair or replace the wiring harness for short, then go to
• Inspect for continuity between generator the next step.
terminal S (wiring harness-side) and battery
plus terminal.
connectors.
(Engine off).
a Clear the DTC from the memory using the
a Run the vehicle under the FREEZE FRAME
• Perform the "After Repair Procedure". (See 01-02B-11 DTC TABLE [WL-C,
01-028-101

dcf010200600w02
DTC P0602 PCM programming error

• No configuration data in the PCM
DETECTION
CONDITION Note
• When the configuration is completed, DTC P0602 is cleared.
POSSIBLE • Complete configuration has not been completed
WE-C].)
(Engine off).
DTC P0606, P2530 [WL-C, WE-C]

dcf01020060Ow03
DTC P0606 PCM malfunction

DTC P2530 PCM (engine switch circuit) malfunction
DETECTION
CONDITION • PCM internal malfunction.
POSSIBLE
1 Replace the PCM.
- - (See 01-40B-9 PCM REMOVAUINSTALLATION [WL-C,
WE-C].)

dcf010200600w04
DTC P0607 PCM performance problem

DETECTION
CONDITION • PCM internal malfunction.
POSSIBLE
CAUSE • PCM internal malfunction
01-028-102
• Has FREEZE FRAME DATA been recorded? the next step.
• Check for related service repair information • If vehicle is not repaired, go to the next step.
3 VERIFY TROUBLESHOOTING OF P0607 Yes Replace the PCM, go to the next step.
• Clear DTC from PCM memory using the
• Is same DTC present?
4 VERIFY AFTER REPAIR PROCEDURE Yes Go to applicable DTC inspection.

dcf010200600w05
DTC P0610 PCM vehicle options error

DETECTION
• PCM data configuration error
CONDITION
POSSIBLE • Configuration procedure has not been completed
(Engine off).
01-028-103
dcf01020060OW06
DTC P0627 Fuel metering valve control circuit open

• The PCM monitors the fuel metering valve driver IC temperature in the PCM and the control voltage while
the engine is running. If either of the following conditions is met, the PCM determines that there is a
malfunction in the fuel metering valve range/performance.
- The PCM monitors the fuel metering valve driver IC temperature in the PCM. If the fuel metering valve
DETECTION
driver IC temperature is more than 150 °C {320 OF} during the fuel metering valve operation, the PCM
CONDITION
determines that the fuel metering valve has a malfunction
- The PCM monitors the fuel metering valve control voltage at the PCM terminals. If fuel metering valve
control voltage is less than 5 V when fuel metering valve is not operating, the PCM determines that the
fuel metering valve has a malfunction (open circuit)
• Fuel metering valve malfunction
POSSIBLE
• Open circuit in wiring harness between fuel metering valve terminal A and main relay
CAUSE
• Open circuit in wiring harness between fuel metering valve terminal Band PCM terminal 179
• PCM malfunction
MAIN RELAY PCM
FUEL METERING VALVE

® ® ® @ (J)
FUEL METERING VALVE PCM

01-028-104

4 INSPECT FUEL METERING VALVE Yes Repair or replace the terminal, then go to Step 9.
• Disconnect the fuel metering valve connector.
5 INSPECT FUEL METERING VALVE CONTROL Yes Go to the next step.
(Engine off).
• Measure the voltage between fuel metering
body ground
6 INSPECT FUEL METERING VALVE Yes Repair the supply pump, then go to Step 9.
• Inspect the fuel metering valve. (See 01-14B-11 SUPPLY PUMP REMOVAU
(See 01-14B-13 FUEL METERING VALVE INSTALLATION [WL-C, WE-C].)
8 INSPECT FUEL METERING VALVE CONTROL Yes Go to the next step.
• Inspect for continuity between fuel metering
PCM terminal 179 (wiring harness-side)
connectors.
(Engine off).
01-028-105
dcf010200600w07
DTC P0628 Fuel metering valve control circuit low input
DETECTION • The PCM monitors the fuel metering valve circuit voltage while the engine is running. If the PCM detects
that the circuit voltage is low when the fuel metering valve is off, the PCM determines that there is a
CONDITION
malfunction in the fuel metering valve circuit (circuit short to ground).
CAUSE • Short to ground in wiring harness between fuel metering valve terminal Band PCM terminal 179
• PCM malfunction
PCM
MAIN RELAY
FUEL METERING VALVE - ~
@
A //
8
@ @ (J)
\\ //
B // ",

124123 122121 120 119118 117 116 115 114113 112 111 110 109 lOB 107 106 105104 103 102101
(LiW) 14B 147 146145 144 143 142141 140 139 13B 137 136 135 134 133132 131 130 129128 127 126125
172 171 170 169 16B 167166 165 164 163 162161 160 159 15B 157 156155 154 153152 151 150 149
196 195 194 193 192 191 190 189 lBB lB7 lB6 lB5 lB4 lB3 lB2 181 lBO 179 17B 177 176 175 174 173
I Gt~ I I Gt~ I
4 INSPECT POOR CONNECTION OF FUEL Yes Repair or replace the suspected terminal, go to Step 8.
METERING VALVE CONNECTOR No Go to the next step.
01-028-106

5 INSPECT FUEL METERING VALVE CIRCUIT Yes Repair or replace the wiring harness for a short to ground,
FOR A SHORT TO GROUND go to Step 8.
• Disconnect the fuel metering valve connector
and PCM connector.
• Inspect for continuity between fuel metering
valve terminal 8 (wiring harness-side) and
body ground.
6 INSPECT FUEL METERING VALVE Yes Repair the supply pump, go to Step 8.
• Inspect the fuel metering valve. (See 01-148-11 SUPPLY PUMP REMOVAU
(See 01-148-13 FUEL METERING VALVE INSTALLATION [WL-C, WE-C].)
7 INSPECT PCM CONNECTOR FOR POOR Yes Repair or replace the suspected terminal, go to the next
CONNECTION step.
connectors.
(Engine off).

dcf010200600w08
DTC P0629 Fuel metering valve control circuit high input

• The PCM monitors the fuel metering valve circuit voltage while the engine is running. If the PCM detects
DETECTION
that the circuit voltage is high when the fuel metering valve is on, the PCM determines that there is a
CONDITION
malfunction in the fuel metering valve circuit (circuit short to power supply).
CAUSE • Short to power supply in wiring harness between fuel metering valve terminal 8 and PCM terminal 179
• PCM malfunction
01-028-107
DTC P0629 Fuel metering valve control circuit high input
PCM
MAIN RELAY
FUEL METERING VALVE

4 INSPECT FUEL METERING VALVE Yes Repair or replace the suspected terminal, go to Step 8.
5 INSPECT FUEL METERING VALVE CIRCUIT Yes Repair or replace the wiring harness for a short to power
FOR SHORT TO POWER SUPPLY supply, go to Step 8.
• Disconnect the fuel metering valve connector No Go to the next step.
and PCM connector.
(Engine off).
• Inspected the voltage between fuel metering
body ground.
01-028-108

6 INSPECT FUEL METERING VALVE Yes Repair the supply pump, go to Step 8.
• Inspect the fuel metering valve. (See 01-14B-11 SUPPLY PUMP REMOVAU
(See 01-14B-13 FUEL METERING VALVE INSTALLATION [WL-C, WE-C].)
7 INSPECT PCM CONNECTOR FOR POOR Yes Repair or replace the suspected terminal, go to the next
CONNECTION step.
connectors.
(Engine off).
• . Clear the DTC from the memory using the

dcf01020060Ow09
DTC P0642 Fuel pressure sensor and boost sensor 5 V circuit low input
DETECTION • The PCM monitors the fuel pressure sensor and the boost sensor 5 V circuit. If the fuel pressure sensor
and boost sensor power voltage is lower than 4.9 V, the PCM determines that there is a fuel pressure
CONDITION
sensor and boost sensor 5 V circuit malfunction.
• Short to ground circuit between circuit in wiring between boost sensor terminal C and PCM terminal 133
• Short to ground circuit between circuit in wiring between fuel pressure sensor terminal C and PCM terminal
POSSIBLE 109
CAUSE • Boost sensor malfunction
• PCM malfunction
01-028-109
DTC P0642 Fuel pressure sensor and boost sensor 5 V circuit low input
PCM
BOOST SENSOR/IAT SENSOR NO.1 5V

WIRING HARNESS-SIDE
CONNEOTOR
1-*-----@----~(J)~1331----4
o ~--------------------~~
FUEL PRESSURE SENSOR @

~--------------------~~109~------+-~J
@
~--------------------~~1401---~O
PCM
105 104 103 102 101

;'~ ,~'" ,~'" """ """ '" """ '" """' ,.,., '00 129 128 127 126 125
lQl~lUl«lalG1Ml~1.1.1~1.1.lMlal.l~lW
lnlrol~1~lDl~1~lMl~1~1~1~1~lAl~1~lY1M 153 152 151 150 149

lM1Ml~1~1~1~lM1Ml~lMl~lMl~1~1~1~1~ln 177 176 175 174 173
recorded?
4 CLASSIFY BOOST SENSORIIAT SENSOR NO.1 Yes Go to the next step.
OR FUEL PRESSURE SENSOR RELATED No Go to Step 10.
MALFUNCTION
(Engine off).
• Is the voltage 4.9 V or less?
01-028-110

connector.
OR HARNESS RELATED MALFUNCTION I-:-N:-o+G:::-o--:t--:o-=S::-te-p-:g:-.- - ' - - - - - - - - - - - - - - - /
connector.
(Engine off).
• Measure the voltage between the Boost sensor
ground.
8 INSPECT BOOST SENSORIIAT SENSOR NO.1 Yes Repair or replace the wiring harness for a possible short to
CIRCUIT FOR SHORT TO GROUND ground, then go to Step 15.
• Inspect for continuity between the boost sensor
ground.
9 INSPECT BOOST SENSORIIAT SENSOR NO.1 Yes Replace the boost sensor/IAT sensor No.1, then go to Step
10 INSPECT FUEL PRESSURE SENSOR Yes Repair or replace the terminal, then go to Step 15.
• Disconnect the fuel pressure sensor connector.
11 CLASSIFY FUEL PRESSURE SENSOR OR Yes Go to the next step.
HARNESS RELATED MALFUNCTION No Go to Step 14.
(Engine off).
• Measure the voltage between the fuel pressure
sensor terminal C (wiring harness-side) and
body ground.
01-028-111

13 INSPECT FUEL PRESSURE SENSOR CIRCUIT Yes Repair or replace the wiring harness for a possible short to
• Inspect for continuity between the fuel pressure
sensor terminal C (wiring harness-side) and
body ground.
14 INSPECT FUEL PRESSURE SENSOR Yes Replace the fuel pressure sensor, then go to the next step.
• Make sure to reconnect all disconnected Nb Go to the next step.
connectors.
(Engine off).

dcf01 0200600w1 0
DTC P0643 Fuel pressure sensor and boost sensor 5 V circuit high input
DETECTION • The PCM monitors the fuel pressure sensor and boost sensor 5 V circuit. If the fuel pressure sensor and
boost sensor power voltage is higher than 4.9 V, the PCM determines that there is a fuel pressure sensor
CONDITION
and boost sensor 5 V circuit malfunction.
• Short to power supply between boost sensor connector terminal C and PCM terminal 133
• Short to power supply between fuel sensor connector terminal C and PCM terminal 109
POSSIBLE • Open circuit in wiring harness between boost sensor connector terminal C and PCM terminal 133
CAUSE • Open circuit in wiring harness between fuel sensor connector terminal C and PCM terminal 109
• PCM malfunction
01-028-112
DTC P0643 Fuel pressure sensor and boost sensor 5 V circuit high input
PCM
BOOST SENSOR!IAT SENSOR NO.1 5V

BOOST SENSOR!
WIRING HARNESS-SIDE IAT SENSOR NO.1
CONNECTOR
CD@ @@@ ®
C
@)@
(m91~ 0
I~~ I A
FUEL PRESSURE SENSOR @)

EW3JJ B 140 0
I~~ I PCM
A 191
124123122121120119118117116115 114113112111110109108107106
191Q1g1~1«1a1.1~1~1~1~1D1.1.1M1.1.1~1W
1n1n1m1~1M1~1M1.1M1~1~1~1~1~1~1~1A1.1M
,~ ,~ '"'~l
129128127126
,ro
153152 151 150
1001%1M1~1.1~1001.1.1~1.1.1M1~1~1~1001n1n 177 176 175 174
recorded?
4 CLASSIFY BOOST SENSOR/IAT SENSOR NO.1 Yes Go to step 14
OR FUEL PRESSURE SENSOR RELATED No If the voltage is 1.0 V or less, go to the next step.
MALFUNCTION If the voltage is 5.1 V or more, go to Step 10.
(Engine off).
sensor/IAT sensor No.1 connector terminal C
and body ground.
•
Is the voltage 5 V constant voltage?
01-028-113

5 INSPECT POOR CONNECTION OF BOOST Yes Repair or replace the terminals, then go to Step 24.
SENSORIIAT SENSOR NO.1 CONNECTOR No Go to the next step.
connector.
• Inspect for poor connection
(damaged, pulled-out terminals, corrosion,
etc.).
• Is there a malfunction?
OR HARNESS RELATED MALFUNCTION No Go to step 8
connector.
(Engine off).
sensor/lAT sensor No.1 connector terminal C
and body ground.
7 INSPECT BOOST SENSORIIAT SENSOR NO.1 Yes Replace the boost sensor, then go to Step 24.
• Inspect the boost sensor/lAT sensor No.1. No Go to Step 24.
8 INSPECT PCM CONNECTOR FOR POOR Yes Repair or replace the pins, then go to Step 24.
etc.).
9 INSPECT BOOST SENSORIIAT SENSOR NO.1 Yes Go to Step 24.
POWER CIRCUIT FOR OPEN No Repair or replace the wiring harness for an open, go to
• Turn the engine switch off. Step 24.
and PCM terminal 133
10 INSPECT POOR CONNECTION OF BOOST Yes Repair or replace the terminals, then go to Step 24.
SENSORIIAT SENSOR NO.1 CONNECTOR No Go to the next step.
connector.
etc.).
11 CLASSIFY BOOST SENSORIIAT SENSOR NO.1 Yes Go to the Step 13.
OR HARNESS RELATED MALFUNCTION No Go to the next step.
connector.
(Engine off).
and body ground.
• Is the voltage 5.1 V or more?
12 INSPECT BOOST SENSORIIAT SENSOR NO.1 Yes Replace the boost sensor, then go to Step 24.
• Inspect the boost sensor/lAT sensor No.1. No Go to Step 24.
01-028-114
Repair or replace the wiring harness for a short to power,

• Turn the engine switch off. go to the Step 24.
• Inspect for poor connection -
etc.).
14 CLASSIFY FUEL PRESSURE SENSOR OPEN
CIRCUIT OR SHORT CIRCUIT RELATED If the voltage is 1.0 V or less, go to the next step.
MALFUNCTION If the voltage is 5.1 V or more, go to Step 20.
(Engine off).
sensor connector terminal C and body ground.
15 INSPECT POOR CONNECTION OF FUEL
PRESSURE SENSOR CONNECTOR
etc.).
16 CLASSIFY FUEL PRESSURE SENSOR OR
HARNESS RELATED MALFUNCTION
(Engine off).
17 FUEL PRESSURE SENSOR
• Inspect the fuel pressure sensor.
(See 01-408-33 FUEL PRESSURE SENSOR
CONNECTION
etc.).
19 INSPECT FUEL PRESSURE SENSOR POWER
CIRCUIT FOR OPEN No Repair or replace the wiring harness for an open, go to
• Inspect for continuity between the fuel pressure
sensor connector terminal C and PCM terminal
109
20 INSPECT POOR CONNECTION OF FUEL
PRESSURE SENSOR CONNECTOR No Go to the next step.
etc.).
01-028-115

21 CLASSIFY FUEL PRESSURE SENSOR OR Yes Go to the Step 23.
HARNESS RELATED MALFUNCTION No Go to the next step.
• Disconnect the fuel pressure sensor connector. i'·'
,1
(Engine off).
22 INSPECT FUEL PRESSURE SENSOR Yes Replace the fuel pressure sensor, then go to Step 24.
• Inspect the fuel pressure sensor. No Go to Step 24.
23 INSPECT PCM CONNECTOR FOR POOR Yes Repair or replace the pins, then go to the next step.
CONNECTION No Repair or replace the wiring harness for a short to power,
• Turn the engine switch off. go to the next step.
etc.).
connectors.
(Engine off).

dcf010200600w11
DTC P0652 CMP sensor and APP sensor 5 V circuit low input
DETECTION • The PCM monitors the CMP sensor and APP sensor 5 V circuit. If the CMP sensor and APP sensor power
voltage is lower than 4.9 V, the PCM determines that there is a CMP sensor and APP sensor 5 V circuit
CONDITION
malfunction.
• Short to ground circuit between circuit in wiring between CMP sensor terminal C and PCM terminal 129
POSSIBLE • Short to ground circuit between circuit in wiring between APP sensor terminal A and PCM terminal 213
CAUSE • CMP sensor malfunction
• APP sensor malfunction
• PCM malfunction
01-028-116
PCM
CMP SENSOR
WIRING HARNESS-SIDE 5V
CMPSENSOR
CONNECTOR
fiJTfJ
@@ @
®
®
APPSENSOR
APP SENSOR
WIRING HARNESS-SIDE
CONNECTOR
0ZfE0
iGt'1 PCM
WIRING HARNESS-SIDE
CONNECTOR
recorded?
01-028-117

4 CLASSIFY CMP SENSOR OR APP SENSOR Yes Go to the next step.
RELATED MALFUNCTION No Go to Step 10.
(Engine off).
• Measure the voltage between the CMP sensor
ground.
5 INSPECT CMP SENSOR CONNECTOR FOR Yes Repair or replace the terminal, then go to Step 15.
6 CLASSIFY CMP SENSOR OR HARNESS Yes Go to the next step.
(Engine off).
ground.
8 INSPECT CMP SENSOR CIRCUIT FOR SHORT Yes Repair or replace the wiring harness for a possible short to
TO GROUND ground, then go to Step 15.
• Inspect for continuity between the CMP sensor
ground.
9 INSPECT CMP SENSOR Yes Replace the CMP sensor, then go to Step 15.
• Inspect the CMP sensor. No Go to Step 15.
(See 01-408-37 CAMSHAFT POSITION
C].)
11 CLASSIFY APP SENSOR OR HARNESS Yes Go to the next step.
(Engine off).
ground.
01-028-118

13 INSPECT APP SENSOR CIRCUIT FOR SHORT Repair or replace wiring harness for a possible short to
TO GROUND round, then go to 15.
• Turn the engine switch off. Go to Step 15.
ground.
14 INSPECT APP
[WL-C, WE-C].)
connectors.
(Engine off).
• Is the same DTC resent?

dcf010200600w12
DTC P0653 CMP sensor and APP sensor 5 V circuit high input
• The PCM monitors the CMP sensor and APP sensor 5 V circuit. If the CMP sensor and APP sensor power
DETECTION
voltage is higher than 5.1 V, the PCM determines that there is a CMP sensor and APP sensor 5 V circuit
CONDITION
malfunction.
• Short to power supply between CMP sensor connector terminal C and PCM terminal 133
• Short to power supply between APP sensor connector terminal A and PCM terminal 213
• Open circuit in wiring harness between CMP sensor connector terminal C and PCM terminal 133
POSSIBLE
• Open circuit in wiring harness between APP sensor connector terminal A and PCM terminal 213
CAUSE
• PCM malfunction
01-028-119
DTC P0653 . CMP sensor and APP sensor 5 V circuit high input
CMP SENSOR
WIRING HARNESS-SIDE 5V
CONNECTOR
@@
fii!fJ
®
PCM
APP SENSOR
APP SENSOR
WIRING HARNESS-SIDE
@@
CONNECTOR
0W0
I~~I
PCM
WIRING HARNESS-SIDE
CONNECTOR
recorded?
4 CLASSIFY CMP SENSOR OR APP SENSOR Yes Go to step 14
RELATED MALFUNCTION No If the voltage is 1.0 V or less, go to the next step.
• Turn the engine switch to the ON position If the voltage is 5.1 V or more, go to Step 10.
(Engine off).
connector terminal C and body ground.
01-028-120

5 INSPECT POOR CONNECTION OF CMP Yes Repair or replace the terminals, then go to Step 24.
SENSOR CONNECTOR No Go to the next step.
etc.).
6 CLASSIFY CMP SENSOR OR HARNESS Yes Go to the next step.
RELATED MALFUNCTION No Go to step 8
(Engine off).
C).}
etc.).
9 INSPECT CMP SENSOR POWER CIRCUIT FOR Yes Go to Step 24.
OPEN No Repair or replace the wiring harness for an open, go to
• Inspect for continuity between the CMP sensor
connector terminal C and PCM terminal 133
10 INSPECT POOR CONNECTION OF CMP Yes Repair or replace the terminals, then go to Step 24.
etc.).
11 CLASSIFY CMP SENSOR OR HARNESS Yes Go to the Step 13.
(Engine off).
C).}
• Turn the engine switch off. go to the Step 24.
etc.).
01-028-121

14 CLASSIFY APP SENSOR OPEN CIRCUIT OR Yes Go to step 24
SHORT CIRCUIT RELATED MALFUNCTION No If the voltage is 1.0 V or less, go to the next step.
• Turn the engine switch to the ON position If the voltage is 5.1 V or more, go to Step 20.
(Engine off).
connector terminal A and body ground.
15 INSPECT POOR CONNECTION OF APP Yes Repair or replace the terminals, then go to Step 24.
etc.).
16 CLASSIFY APP SENSOR OR HARNESS Yes Go to the next step.
RELATED MALFUNCTION No Go to step 18
(Engine off).
• Inspect the APP sensor. No Go to Step 24.
[WL-C, WE-C].)
etc.).
19 INSPECT APP SENSOR POWER CIRCUIT FOR Yes Go to Step 24.
OPEN No Repair or replace the wiring harness for an open, go to
connector terminal A and PCM terminal 213.
20 INSPECT POOR CONNECTION OF APP Yes Repair or replace the terminals, then go to Step 24.
etc.).
21 CLASSIFY APP SENSOR OR HARNESS Yes Go to the Step 23.
(Engine off).
• Inspect the APP sensor. No Go to Step 24.
[WL-C, WE-C].)
01-028-122

etc.).
connectors.
(Engine off).
• Is the same DTC n."..:":>lnT·,

dcf01020060Ow13
DTC P0660Intake shutter solenoid valve (half) control circuit open

• The PCM monitors the intake shutter solenoid valve (half) control signal. If the following conditions are
detected, the PCM determines that the intake shutter solenoid valve (half) control circuit has a malfunction.
DETECTION - The PCM turns the intake shutter solenoid valve (half) off, but the intake shutter solenoid valve (half)
CONDITION control voltage is less than 5 V for 2 s (open circuit)
- The PCM internal driver IC temperature is more than 150 °C {320 OF} when the intake shutter solenoid
valve (half) is on
• Intake shutter solenoid valve (half) malfunction
POSSIBLE • Open circuit in wiring harness between intake shutter solenoid valve (half) terminal A and main relay
CAUSE • Open circuit in wiring harness between intake shutter solenoid valve (half) terminal Band PCM terminal
152
• PCM malfunction
VALVE (HALF) PCM
MAINRELAY~
®1 ~ A B ~ @
~~ I
@
PCM
~mTh
124123122121 120119118117116115114113112111 110109108107106
1~lQl~1~1«lalgl~1~1~1~lDl.l.1Ml~1~1~1~
lnlnlrol~l~l~l~l.l.l~l.l~l~lWl~l~l~l~lM iii
196 195 194 193 192 191 190 189 188 187 186 185 184 183 182 181 180 179 178 17711761175117411731111
I~~I I~~I
01-028-123
4 INSPECT INTAKE SHUTTER SOLENOID VALVE Yes Repair or replace the terminal, then go to Step 9.
(HALF) CONNECTOR FOR POOR No Go to the next step.
CONNECTION
• Disconnect the intake shutter solenoid valve
(half) connector.
5 INSPECT INTAKE SHUTTER SOLENOID VALVE Yes Go to the next step.
(HALF) CONTROL CIRCUIT FOR OPEN No Repair or replace the wiring harness for a pos:,?ible open
CIRCUIT circuit, then go to Step 9.
(Engine off).
• Measure the voltage between intake shutter
solenoid valve (half) terminal A (wiring
6 INSPECT INTAKE SHUTTER SOLENOID VALVE Yes Replace the intake shutter solenoid valve (half), then go to
(HALF) Step 9.
• Inspect the intake shutter solenoid valve (half). (See 01-13B-3INTAKE-AIR SYSTEM REMOVAU
(See 01-16B-6INTAKE SHUTTER SOLENOID
VALVE (HALF) INSPECTION [WL-C, WE-C].) No Go to the next step.
(HALF) CONTROL CIRCUIT FOR OPEN No Repair or replace the wiring harness for a possible open
CIRCUIT circuit, then go to the next step.
• Inspect for continuity between intake shutter
solenoid valve (half) terminal B (wiring
harness-side)
01-028-124
Yes Replace the PCM, then go to the next step.

(See 01-40B-9 PCM REMOVAUINSTALLATION [WL-C,
connectors.
(Engine off).
• Are DTCs 'Vc":",,n'"
DTC P0661 Intake shutter solenoid valve (half) control circuit low input
• The PCM monitors the intake shutter solenoid valve (half) control signal at PCM terminal 152. If the PCM
DETECTION
turns the intake shutter solenoid valve (half) off but the voltage at PCM terminal 152 remains low, the PCM
CONDITION
determines that intake shutter solenoid valve (half) circuit has a malfunction (circuit short to ground).
• Intake shutter solenoid valve malfunction
• Short to ground in wiring harness between intake shutter solenoid valve (half) terminal Band PCM terminal
POSSIBLE
152
CAUSE
• PCM malfunction
MAIN RELAY PCM

INTAKE SHUTTER
SOLENOID VALVE (HALF)
® ®
PCM
120119118117116115114113112111 110109108107106105104103102101
1~lMl~1~1~lMl~1~1~1~1.1~lDl~1.lMlglgl~1~10
1~1.1~1001~lMl~1~1~lMl~1~1~lM1MlnlnlnlnlMln
01-028-125
CONNECTION
(half).
(HALF) MALFUNCTION No Replace the intake shutter solenoid valve (half), then go to
• Perform intake shutter solenoid valve (half) step 8.
inspection.
(See 01-16B-6 INTAKE SHUTTER
SOLENOID VALVE (HALF) INSPECTION [WL-
C, WE-C].)
• Is intake shutter solenoid valve normal?
6 INSPECT INTAKE SHUTTER SOLENOID VALVE Yes Repair or replace the wiring harness for short to ground,
CONTROL CIRCUIT FOR SHORT TO GROUND then go to Step 8.
• Inspect for continuity between intake shutter No Go to the next step.
solenoid valve (half) valve terminal B (wiring
connectors.
(Engine off).
01-028-126
dcf01020060Ow15
DTC P0662 Intake shutter solenoid valve (half) control circuit high input
• The PCM monitors the intake shutter solenoid valve (half) control signal at PCM terminal 152. If the PCM
DETECTION turns the intake shutter solenoid valve (half) on but the voltage at PCM terminal 152 remains high, the
CONDITION PCM determines that the intake shutter solenoid valve (half) circuit has a malfunction (circuit short to power
supply).
• Intake shutter solenoid valve (half) malfunction
• Short to power supply in wiring harness between intake shutter solenoid valve (half) terminal Band PCM
POSSIBLE
terminal 152
CAUSE
• Shorted intake shutter solenoid valve (half) or PCM connector
• PCM malfunction
MAIN RELAY PCM
PCM
124 123 122 121 120 119 118 117 116 115 114113 112 111 110 109 108 107 106 105 104 103 102 101
148 147 146 145 144 143 142 141 140 139 138 137 136 135 134 133 132 131 130 129 128 127 126 125
172 171 170 169 168 167 166 165 164 163 162 161 160 159 158 157 156 155 154 153 152 151 150 149
196 195 194 193 192 191 190 189 188 187 186 185 184 183 182 181 180 179 178 177 176 175 174 173
CONNECTION
(half) connector.
(HALF) MALFUNCTION No Replace the intake shutter solenoid valve (half), then go to
• Perform intake shutter solenoid valve (half) Step 7.
inspection.
(See 01-16B-6INTAKE SHUTTER
SOLENOID VALVE (HALF) INSPECTION [WL-
C, WE-C].)
• Is the intake shutter solenoid valve (half)
normal?
01-028-127

6 INSPECT INTAKE SHUTTER SOLENOID VALVE Yes Repair or replace the wiring harness for short to power
(HALF) CONTROL CIRCUIT SHORT TO POWER supply, then go to the next step.
(Engine off).
solenoid valve (half) terminal B (wiring
connectors.
(Engine off).

dcf010200600w16
DTC P0663Intake shutter solenoid valve (full) control circuit open

• The PCM monitors the intake shutter solenoid valve (full) control signal. If the following conditions are
detected, the PCM determines that the intake shutter solenoid valve (full) control circuit has a malfunction.
DETECTION - The PCM turns the intake shutter solenoid valve (full) off, but the intake shutter solenoid valve (full)
CONDITION control voltage is less than 5 V for 2 s (open circuit)
- The PCM internal driver IC temperature is more than 150°C {320 OF} when the intake shutter solenoid
valve (full) is on
• Intake shutter solenoid valve (full) malfunction
CAUSE • Open circuit in wiring harness between intake shutter solenoid valve (full) terminal A and main relay
• Open circuit in wiring harness between intake shutter solenoid valve (full) terminal Band PCM terminal 155
• PCM malfunction
01-028-128
MAIN RELAY PCM

INTAKE SHUTTER
SOLENOID VALVE (FULL)
® @ @
INTAKE SHUTTER SOLENOID VALVE (FULL) PCM

'N'~ '" '" ,,, "" " .." " .." ". """ '" "",00 '00 ""00 .... 00 ""~I
l~lQl~lglMlalal~l~l~l~l~l.l.lMlal~l~l~lnl~lVl~
172171 170169168 167 166 165 164163 162 161160 159 158 157 156155154153152151 150
l00l~lMl~l.l~l00l~lMl~lMl~lMl.l~l~l00l~lnlnlNlnlM
• Is any related ~epair information available?
(FULL) CONNECTOR FOR POOR No Go to the next step.
CONNECTION
(full) connector.
(FULL) CONTROL CIRCUIT FOR OPEN No Repair or replace the wiring harness for a possible open
CIRCUIT circuit, then go to Step 9.
(Engine off).
• Measure the voltage between Intake shutter
solenoid valve (full) terminal A (wiring harness-
side) and body ground
01-028-129

6 INSPECT INTAKE SHUTTER SOLENOID VALVE Yes Replace the intake shutter solenoid valve (full), then go to
(FULL) Step 9.
• Inspect the intake shutter solenoid valve (full). (See 01-13B-3INTAKE-AIR SYSTEM REMOVAU
(See 01-16B-7 INTAKE SHUTTER SOLENOID
VALVE (FULL) INSPECTION [WL-C, WE-C].) No Go to the next step.
(FULL) CONTROL CIRCUIT FOR OPEN No Repair or replace the wiring harness for a possible open
CIRCUIT circuit, then go to the next step.
solenoid valve (full) terminal B (wiring harness-
side) and PCM terminal 155 (wiring harness-
side)
connectors.
(Engine off).
current diagnostic. tool.
(See 01-02B-1 0 AFTER REPAIR No Troubleshooting completed.

dcf010200600w17
DTC P0664 Intake shutter solenoid valve (full) control circuit low input
DETECTION • The PCM monitors the intake shutter solenoid valve (full) control signal at PCM terminal 155. If the PCM
turns the intake shutter solenoid valve (full) off, but the voltage at PCM terminal 155 remains low, the PCM
CONDITION
determines that intake shutter solenoid valve (full) circuit has a malfunction (circuit short to ground).
POSSIBLE • Short to ground in wiring harness between intake shutter solenoid valve (full) terminal Band PCM terminal
155
CAUSE
• PCM malfunction
01-028-130
MAIN RELAY PCM

INTAKE SHUTTER
SOLENOID VALVE (FULL)
@ @ @
INTAKE SHUTTER SOLENOID VALVE (FULL) PCM

'""""li
124123122121 120119118117116115114113112111 110109108107106
1~1Q1g1U1«1a1a1~1~1~1~1~1~1.1M1a1.1~1M 129128127
1n1n1ro1~1M1~1~1E1M1~1~1~1001~1~1~1~1~1M 153152151
1001001M1~1~1~1~1~1M1~1~1E1M1~1~1~1001~1n 177 176 175
• Connect the current diagnostic tool to the DLC- Perform the "INTERMITIENT CONCERNS
CONNECTION
(full) connector.
(FULL) MALFUNCTION No Replace the intake shutter solenoid valve (full), then go to
• Perform intake shutter solenoid valve (full) step 8.
inspection.
(See 01-16B-7INTAKE SHUTIER
SOLENOID VALVE (FULL) INSPECTION [WL-
C, WE-C).)
• Is intake shutter solenoid valve (full) normal?
01-028-131

6 INSPECT INTAKE SHUTTER SOLENOID VALVE Yes Repair or replace the wiring harness for short to ground,
(FULL) CONTROL CIRCUIT FOR SHORT TO then go to Step 8.
(full) connector and PCM connector.
connectors.
(Engine off).

dcf010200600w18
DTC P0665 Intake shutter solenoid valve (full) control circuit high input
• The PCM monitors the intake shutter solenoid valve (full) control signal at PCM terminal 155. If the PCM
DETECTION turns the intake shutter solenoid valve (full) on, but the voltage at PCM terminal 155 remains high, the PCM
CONDITION determines that the intake shutter solenoid valve (full) circuit has a malfunction (circuit short to power
supply).
POSSIBLE • Short to power supply in wiring harness between intake shutter solenoid valve (full) terminal Band PCM
terminal 155
CAUSE
• Shorted intake shutter solenoid valve (full) or PCM connector
• PCM malfunction
" "".
01-028-132
MAIN RELAY PCM
INTAKE SHUTIER SOLENOID VALVE (FULL) PCM

124 123 122 121 120 119 118 117 116 115 114 113112 111 110 109 108107 106 105 104 103 102 101
148 147 146 145 144 143 142141 140 139 138 137136 135 134 133 132131 130 129 128 127 126 125
172 171 170 169 168167 166165 164 163 162 161160 159 158 157 156155 154 153 152 151 150 149
196 195 194 193 192 191 190 189 188 187 186 185184 183 182 181 180179 178 177 176 175 174 173
3 INSPECT INTAKE SHUTIER SOLENOID VALVE Yes Repair or replace the terminal, then go to Step 7.
CONNECTION
(full) connector.
4 INSPECT INTAKE SHUTIER SOLENOID VALVE Yes Go to the next step.
(FULL) MALFUNCTION No Replace the intake shutter solenoid valve (full), then go to
• Perform intake shutter solenoid valve (full)
inspection.
Step 7. -
(See 01-16B-7INTAKE SHUTIER
SOLENOID VALVE (FULL) INSPECTION [WL-
C, WE-C].)
• Is the intake shutter solenoid valve (full)
normal?
01-028-133

6 INSPECT INTAKE SHUTTER SOLENOID VALVE Yes Repair or replace the wiring harness for short to power
(FULL) CONTROL CIRCUIT SHORT TO POWER supply, then go to the next step.
(Engine off).
7 VERIFY TROUBLESHOOTING OF DTC POGGS Yes Replace the PCM, then go to the next step.
• Turn the engine switch off. WE-GJ.)
connectors.
(Engine off).

dcf010200600w19
DTC POG8S Main relay control circuit open
DETECTION • The PCM monitors the power supply to the PCM. If the power supply is shut down several times when the
engine switch is turned to the ON position, the PCM determines that there is a power circuit malfunction
CONDITION
(open circuit).
• Open circuit in wiring harness between main relay terminal Band PCM terminal 219
POSSIBLE • Open circuit in wiring harness betwee:n main relay terminal 0 and PCM terminal 201, 203, or 205
CAUSE • Main relay malfunction
• Open circuit in wiring between main relay terminal A, terminal C and battery
• PCM malfunction
01-028-134
BATTERY PCM
MAIN RELAY
® (j)
® (j)
® (j)
® (j)
MAIN RELAY WIRING PCM WIRING HARNESS-SIDE

HARNESS-SIDE CONNECTOR
CONNECTOR
rc1Al
[Eli]
. recorded?
3 VERIFY CURRENT SIGNAL STATUS: IS Yes Go to the next step. .
the current diagnostic tool. TROUBLESHOOTING [WL-C, WE-C).}
4 INSPECT MAIN RELAY CONNECTOR FOR Yes Repair or replace the terminals, then go to Step 9.
• Disconnect the generator connector.
• Inspect for poor connection (damaged, pulled-
01-028-135

5 INSPECT MAIN RELAY POWER CIRCUIT FOR Yes Go to the next step.
OPEN CIRCUIT No Repair or replace the wiring harness for open circuit, then
• Measure the voltage between the following go to Step 9.
terminal:
- Main relay terminal A and body ground.
- Main relay terminal C and body ground.
6 INSPECT MAIN RELAY Yes Replace the main relay, then go to Step 9.
• Inspect the main relay. No Go to the next step.
7 INSPECT PCM CONNECTOR FOR POOR Yes Repair terminals, then go to Step 9.
• Turn the engine switch ott.
• Disconnect the PCM connector. ,
• Inspect for poor connection (damaged, pulled-
8 INSPECT MAIN RELAY CONTROL CIRCUIT Yes Go to the next step.
FOR OPEN CIRCUIT No Repair or replace the wiring harness for open circuit, then
• Inspect for continuity between the following go to Step 9.
terminal:
- Main relay terminal Band PCM terminal 219
- Main relay terminal D and PCM terminal
201,203,or205
9 VERIFY THAT DTC P0685 TROUBLESHOOTING Yes Replace PCM, then go to the next step.
• Turn the engine switch ott. WE-C].)
connectors.
(Engine ott).
DTC P069S [WL-C, WE-C]

dcf010200600w20
DTC P0698 EGR valve position sensor 5 V circuit low input

DETECTION • The PCM monitors the EGR position sensor 5 V circuit. If the EGR position sensor power voltage is lower
CONDITION than 4.9 V, the PCM determines that there is a EGR position sensor 5 V circuit malfunction.
• Short to ground circuit between circuit in wiring between EGR position sensor terminal Band PCM terminal
POSSIBLE 108
CAUSE • EGR position sensor malfunction
• PCM malfunction
01-028-136
DTC P0698 EGR valve position sensor 5 V circuit low input
EGRVALVE
POSITION SENSOR PCM
® @@
----~ B ~~--------------~
A ~~--------------~

PCM
recorded?
4 INSPECT EGR POSITION SENSOR Yes Repair or replace the terminal, then go to Step 9.
• Disconnect the EGR position sensor
connector.
01-028-137

5 CLASSIFY EGR POSITION SENSOR OR Yes Go to the next step.
HARNESS RELATED MALFUNCTION No Go to Step 8.
connector.
(Engine off).
• Measure the voltage between the EGR position
sensor terminal B (wiring harness-side) and
body ground.
7 INSPECT EGR POSITION SENSOR CIRCUIT Yes Repair or replace the wiring harness for a possible short to
• Inspect for continuity between the EGR
position sensor terminal B (wiring harness-
8 INSPECT EGR POSITION SENSOR Yes Replace the EGR position sensor, then go to the next step.
• Inspect the EGR position sensor. No Go to the next step.
(See 01-40B-40 EGR VALVE POSITION
SENSOR INSPECTION [WL-C, WE-C).)
connectors.
(Engine off).

dcf010200600w21
DTC P0699 EGR valve position sensor 5 V circuit high input

DETECTION • The PCM monitors the EGR position sensor 5 V circuit. If the EGR position sensor power voltage is higher
CONDITION than 5.1 V, the PCM determines that there is a EGR position sensor 5 V circuit malfunction.
• Short to power supply between EGR position sensor connector terminal Band PCM terminal 108
POSSIBLE • Open circuit in wiring harness between EGR position sensor connector terminal Band PCM terminal 108
CAUSE • EGR position sensor malfunction
• PCM malfunction
01-028-138
DTC P0699 EGR valve position sensor 5 V circuit high input
EGRVALVE
POSITION SENSOR PCM
@@
@@@ ®
r---~ B ~----------------~
~.~~ C ~----------------~

PCM
124123 122 121 120 119 118 117 116 115 114 113112 111 110 109 108 107 106 105 104 103 102 101
148147 146 145 144 143 142 141 140 139 138 137 136 135 134 133 132131 130 129 128 127 126125
172171 170 169 168 167 166 165 164 163 162161 160 159 158 157 156155 154 153 152 151 150149
196195 194 193 192 191 190 189 188 187 186 185 184 183 182 181 180179 178 177 176 175 174173
1 VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to the next step. •
recorded?
4 CLASSIFY EGR POSITION SENSOR OPEN Yes Go to step 10
CIRCUIT OR SHORT CIRCUIT RELATED No Go to the next step.
MALFUNCTION
(Engine off).
sensor connector terminal B and body ground.
5 INSPECT POOR CONNECTION OF EGR Yes Repair or replace the terminals, then go to Step 14.
POSITION SENSOR CONNECTOR No Go to the next step.
connector.
etc.).
01-028-139

6 CLASSIFY EGR POSITION SENSOR OR Yes Go to the next step.
HARNESS RELATED MALFUNCTION No Go to step 8
connector.
(Engine off).
sensor connector terminal 8 and body ground.
7 INSPECT EGR POSITION SENSOR Yes Replace the EGR position sensor, then go to Step 14.
• Inspect the EGR position sensor. No Go to Step 14.
(See 01-408-40 EGR VALVE POSITION
SENSOR INSPECTION [WL-C, WE-C].)
etc.).
9 INSPECT EGR POSITION SENSOR POWER Yes Go to Step 14.
CIRCUIT FOR OPEN No Repair or replace the wiring harness for an open, go to
• Inspect for continuity between the EGR
position sensor position sensor connector
terminal 8 and PCM terminal 108.
10 INSPECT POOR CONNECTION OF EGR Yes Repair or replace the terminals, then go to Step 14.
POSITION SENSOR CONNECTOR No Go to the next step.
connector.
etc.).
11 CLASSIFY EGR POSITION SENSOR OR Yes Go to the Step 13.
HARNESS RELATED MALFUNCTION No Go to the next step.
connector.
(Engine off).
sensor connector terminal 8 and body ground.
12 INSPECT EGR POSITION SENSOR Yes Replace the EGR position sensor, then go to Step 14.
• Inspect the EGR position sensor. No Go to Step 14.
(See 01-408-40 EGR VALVE POSITION
SENSOR INSPECTION [WL-C, WE-C).}
13 INSPECT PCM CONNECTOR FOR POOR Yes Repair or replace the pins, then go to the next step.
• Turn the engine switch off. go to the next step.
etc.).
01-028-140

• Turn the engine switch off. WE-C].) .
connectors.
(Engine off).
DTC P1196 Key off voltage high input

• The PCM monitors whether the main relay opens after 2 5 when the engine switch is turned to the off
DETECTION
position. If the main relay does not open after 2 5, the PCM determines that there is malfunction in the
CONDITION
main relay circuit.
• Main relay malfunction
CAUSE • Short to power supply between main relay terminal D and PCM terminal 201, 203, and 205
• PCM malfunction
BATTERY
PCM
MAIN RELAY
@
l*::--~~---<H201 }----o
~~H205}----n
MAIN RELAY PCM

icTAl
~
01-028-141
DATA No Go to troubleshooting procedures for DTC in FREEZE
• Is DTC P1196 on FREEZE FRAME DATA? FRAME DATA.
(See 01-02B-11 DTC TABLE [WL-C, WE-C].)
4 INSPECT MAIN RELAY CONNECTOR FOR Yes Repair or replace terminal, then go to Step 7.
• Disconnect the main relay connector.
5 INSPECT MAIN RELAY Yes Go to the next step.
• Inspect the main relay. No Install the sensor securely, then go to the Step 7.
• Is it normal?
6 INSPECT MAIN RELAY CIRCUIT FOR SHORT Yes Repair or replace for short to power supply.
TO POWER SUPPLY Then, go to the next step.
• Measure voltage between main relay terminal
D (wiring harness-side) and body ground.
connectors.
(Engine off).

dcf010201200w02
DTC P1259 IMMOBILIZER to PCM signal error

DETECTION
• The PCM does not complete target ID transfer.
CONDITION
POSSIBLE • Immobilizer system malfunction

CAUSE • Communication error between immobilizer unit and PCM
• PCM malfunction
01-028-142
nr(l~""nure
FREEZE FRAME DATA AND

DIAGNOSTIC MONITORING TEST RESULTS Record the FREEZE FRAME DATA and DIAGNOSTIC
been recorded?
2 VERIFY RELATED REPAIR INFORMATION Yes Go to appropriate DTC troubleshooting procedure.
AVAILABILITY (See 09-02A-2 DTC TABLE [IMMOBILIZER SYSTEM].)
• Verify related service repair information No go to the next step.
availability.
3 INSPECT IMMOBILIZER UNIT CONNECTOR Yes Repair or replace the suspected terminal, then go to Step
• Turn engine switch off. No Go to the next step.
• Disconnect the IMMOBILIZER UNIT connector.
4 INSPECT COMMUNICATION LINE FOR SHORT Yes Repair or replace the suspected wiring harness, then go to
TO GROUND Step 8.
• Inspect for continuity between the following No Go to the next step.
-IMOBILIZER unit connector terminal A
5 PECT COMMUNICATION LINE FOR SHORT Yes r or replace the suspected wiring harness, then go to
TO POWER SUPPLY 8.
• Measure the voltage between following No Go to the next step.
-IMMOBILIZER unit connector terminal A
CONNECTION 8.
• Turn engine switch off. No Go to the next step.
(See 01-40B-9 PCM REMOVAU
7 INSPECT COMMUNICATION LINE FOR OPEN
CIRCUIT Repair or replace the suspected wiring harness, then go to
• Inspect for continuity between the following the next step.
terminals:
-IMMOBILIZER UNIT connector terminal A
(wiring harness-side) and PCM connector
terminal 230 (wiring harness-side)
8 VERIFY THAT DTC P1259 Replace then go to the next step.
• Start the engine and warm-up to normal
operating temperature.
• Retrieve the DTC using the current diagnostic
tool.
• Is the PENDING CODE same DTC present?
9 VERIFY AFTER REPAIR PROCEDURE o to the applicable DTC inspection.
01-028-143

dcf010201200w03
DTC P1260 Theft detected Vehicle immobilizer

DETECTION
CONDITION •
Immobilizer system malfunction

1 VERIFY FREEZE FRAME DATA AND Yes go to the next step.
DIAGNOSTIC MONITORING TEST RESULTS No Record the FREEZE FRAME DATA and DIAGNOSTIC
been recorded?
• Verify related service repair information If the vehicle is not repaired, go to the next step.
availability. No go to the next step.
3 VERIFY STORED DTC IN IMMOBILIZER Yes Go to appropriate DTC troubleshooting procedure.
SYSTEM (See 09-02A-2 DTC TABLE [IMMOBILIZER SYSTEM].)
• Turn the engine switch to the ON position No go to the next step.
(Engine off).
• Verify stored DTC in IMMOBILIZER SYSTEM.
(See 09-02A-2 DTC TABLE [IMMOBILIZER
SYSTEM].)
• Are DTCs stored?
4 VERIFY THAT DTC P1260 TROUBLESHOOTING Yes Replace PCM, then go to the next step.
tool.
• Perform "After Repair Procedure". (See 01-02B-11 DTC TABLE [WL-C, WE-C].)
• Is there any DTC present?

dcf010201300w03
DTC P1391 Glow plug control circuit low input
DETECTION • The PCM monitors the output signal to the glow plug relay when the glow plug relay is on. If the glow plug
relay voltage is less than 2 V for 1 s when the glow plug relay is operating, The PCM determines that there
CONDITION
is a malfunction in the glow plug relay circuit.
• Melt or burnt glow fuse
• PCM malfunction
CAUSE • Open circuit in wiring harness between glow plug relay terminal 3A and PCM terminal 227
• Open circuit in wiring harness between glow plug relay terminal1A and PCM terminal 182
• Open circuit in wiring harness between glow plug relay terminal 1B and main relay
• Open circuit in wiring harness between glow plug relay terminal 2A and battery
01-028-144
BATTERY PCM
GLOW
FUSE GLOW PLUG RELAY
L-..:::®~--"@~ 2A 1
!-7r'=@=-----=-,----"'----(@-=
°-*l227J----.----()
GLOW
MAIN RELAY PLUG
®
GLOW PLUG RELAY
PCM
~
DB
GLOW PLUG 4 243 242 241 240 239 238 237 236 235 234 233
WIRING HARNESS-SIDE CONNECTOR 7256 255 254 253 252251 250249248 247 246
4 GLOW PLUG CONNECTOR FOR POOR Yes Repair or replace the terminal, then go to Step 13.
pulled- out terminals, corrosion).
01-028-145
ON-BOARD DIAGNOSTIC IWL-C, WE-C]

5 INSPECT GLOW PLUG RELAY CONNECTOR Yes Repair or replace the terminal, then go to the next step.
6 INSPECT GLOW PLUG RELAY POWER SUPPLY Yes Go to the next step.
FOR OPEN CIRCUIT No Repair or replace the wiring harness for an open circuit, go
• Turn the engine switch off. to Step 13.
terminal 2A and body ground.
7 INSPECT GLOW PLUG RELAY CONTROL Yes Repair or replace the wiring harness for an open circuit, go
POWER FOR OPEN CIRCUIT to Step 13.
• Remove the glow plug relay.
terminal 18 and ground.
8 INSPECT GLOW PLUG RELAY SIGNAL FOR Yes Repair or replace the wiring harness for an open circuit, go
OPEN CIRCUIT to Step 13.
(Engine off).
terminal 1A.
• Is voltage less than 2 V?
9 INSPECT GLOW PLUG RELAY Yes Go to the next step.
• Inspect the glow plug relay. No Replace the glow plug relay, go to Step 13.
(See 01-138-9 GLOW PLUG RELAY
10 INSPECT POOR CONNECTION OF PCM Yes Repair or replace the suspected terminal, go to Step 13.
CONNECTOR No Go to the next step.
11 INSPECT GLOW PLUG RELAY SIGNAL Yes Repair or replace the wiring harness for a short to ground,
CIRCUIT FOR SHORT TO GROUND then go to Step 13.
• Turn the engine switch off. No Go to the next step
• Remove the glow plug relay connector.
12 INSPECT GLOW PLUG RELAY SIGNAL Yes Go to the next step
CIRCUIT FOR OPEN CIRCUIT No Repair or replace the wiring harness for an open circuit,
terminal 3A and PCM terminal 227.
• Turn the engine switch off. WE-C).}
connectors.
(Engine off).
01-028-146

DTC P1392 Glow plug control circuit high input

• The PCM monitors the output signal to the glow plug relay when the glow plug relay is off. If the glow plug
DETECTION
relay voltage is more than 2 V for 1 s when the glow plug relay is off, The PCM determines that there is a
CONDITION
malfunction in the glow plug relay control circuit.
POSSIBLE • PCM malfunction
• Short to power supply in wiring harness between glow plug relay terminal 3A and PCM terminal 227
• Short to ground in wiring harness between glow plug relay terminal 1A and PCM terminal 182
BATTERY PCM
GLOW
FUSE GLOW PLUG RELAY
@
' - - - - - - * I 2A
@ @ 227 )----.--0
GLOW
MAIN RELAY PLUG
GLOW PLUG RELAY

PCM
~
o
GLOW PLUG
01-028-147
4 INSPECT GLOW PLUG RELAY CONNECTOR Yes Repair or replace the terminal, then go to the next step.
5 INSPECT GLOW PLUG RELAY Yes Replace the glow plug relay, go to Step 10.
• Inspect the glow plug relay. No Go to the next step.
(See 01-13B-9 GLOW PLUG RELAY
6 INSPECT GLOW PLUG RELAY SIGNAL Yes Repair or replace the wiring harness for a short to power
CIRCUIT FOR SHORT TO POWER supply, then go to Step 10.
• Turn the engine switch to the ON position No Go to the next step
(Engine off).
• Measure the voltage between glow plug
• Is the voltage more than 2 V?
7 INSPECT GLOW PLUG Yes Replace the glow plug, go to Step 10.
• Inspect glow plug. No Go to the next step.
(See 01-13B-9 GLOW PLUG INSPECTION
[WL-C, WE-C].)
8 INSPECT POOR CONNECTION OF PCM Yes Repair or replace the suspected terminal, go to the Step
CONNECTOR 10.
9 INSPECT GLOW PLUG RELAY CONTROL Yes Repair or replace the wiring harness for a short to power
POWER CIRCUIT FOR SHORT TO GROUND supply, then go to the next step.
• Turn the engine switch to off. No Go to the next step
• Remove the glow plug relay.
01-028-148
VERIFY TROUBLESHOOTING OF DTC P1392 Yes Replace the PCM, go to the next step.
connectors.
(Engine off).
11 VER AFTER REPAIR RE Yes to the applicable DTC inspection.
• Perform the "After Repair Procedure". 01-02B-11 DTC TABLE [WL-C, WE-C].
DTC P1602 Immobilizer/PCM communication error

DETECTION
• PCM internal malfunction
CONDITION
POSSIBLE
• PCM malfunction
CAUSE
1 Replace PCM, then go to the next step.
- (See 01-40B-9 PCM REMOVAUINSTALLATION [WL-C,
WE-C].)

dcf010201600w03
DTC P1603 ID Number Unregistered

DETECTION
• PCM internal malfunction
CONDITION
POSSIBLE
• PCM malfunction
CAUSE
WE-C].)
01-028-149
dcf01020160OW04
DTC P1604 Code word unregistered

DETECTION
CONDITION
POSSIBLE
PCM malfunction
CAUSE
WE-C).)
DTC P1621, P1622, P1623, P1624 [WL-C, WE-C]

dcf01020160OW05
DTC P1621 Immobilizer code word does not match

DTC P1622 Immobilizer ID does not match
DTC P1623 Immobilizer code word/lD number write failure
DTC P1624 Anti-theft system
DETECTION • Cord word stored in immobilizer system and PCM does not to match.
CONDITION • ID number stored in immobilizer system and PCM does not to match.
1 VERIFY FREEZE FRAME DATA AND Yes go to the next step.
DIAGNOSTIC MONITORING TEST RESULTS No Record the FREEZE FRAME DATA and DIAGNOSTIC
been recorded?
• Verify related service repair information If the vehicle is not repaired, go to the next step.
availability. No go to the next step.
3 VERIFY STORED DTC IN IMMOBILIZER Yes Go to appropriate DTC troubleshooting procedure.
SYSTEM (See 09-02A-2 DTC TABLE [IMMOBILIZER SYSTEM].)
• Turn the engine switch to the ON position No go to the next step.
(Engine off).
• Verify stored DTC in IMMOBILIZER SYSTEM.
(See 09-02A-2 DTC TABLE [IMMOBILIZER
SYSTEM].)
4 VERIFY THAT DTC P1621/P16221P1623/P1624 Yes Replace PCM, then go to the next step.
TROUBLESHOOTING IS COMPLETED (See 01-40B-9 PCM REMOVAUINSTALLATION [WL-C,
tool.
01-028-150
RE
• Perform the "After Repair Procedure".
DTC P1675 Injection quantity adjustment value writing error

DETECTION
• The fuel injector compensation data configuration has not been completed.
CONDITION
POSSIBLE • Fuel injector compensation data input procedure does not been completed.
3 VERIFY FUEL INJECTOR COMPENSATION Yes Go to the next step.
DATA INPUT PROCEDURE No Perform the fuel injector compensation data input
• Does the fuel injector compensation data input procedure.
procedure properly? (See 01-14B-15 FUEL INJECTOR REMOVAU
INSTALLATION [WL-C, WE-C).)
• Turn the engine switch to ON position (engine
off).
• Clear the DTC from PCM memory using the
01-028-151
dcf01020160OW07
DTC P1676 Injection quantity adjustment value checksum error

DETECTION
CONDITION • The fuel injector compensation data check sum error.
POSSIBLE
CAUSE • Fuel injector compensation data reprogramming error.
3 VERIFY FUEL INJECTOR COMPENSATION Yes Go to the next step.
DATA INPUTTED PROPERLY No Clear the learning data on PCM. Perform the fuel injector
• Perform the fuel injector compensation data compensation data input procedure again.
input procedure.
(See 01-14B-15 FUEL INJECTOR REMOVAU
• Does the inputted fuel injector compensation
data properly?
WE-C].)
• Turn the engine switch to ON position (engine
off).
• Clear the DTC from PCM memory using the

dcf010202100w01
DTC P2135 Accelerator pedal position (APP) sensor No.1/No.2 voltage correlation problem
• The PCM monitors the input signals from accelerator pedal position sensor No.1 and accelerator pedal
DETECTION position sensor No.2. If the difference between accelerator pedal position sensor No.1 and accelerator
CONDITION pedal position sensor No.2 is more than 0.9 V for 0.5 s, the PCM determines that there is a malfunction in
the accelerator pedal position sensor characteristic.
POSSIBLE • APP sensor malfunction
01-028-152
Intermittent concern exists.

2. TROUBLESHOOTING" .
4 PECT APP S""."",...,"
[WL-C, WE-C).)
connectors.
(Engine off).
• Are any DTCs nroc>on,t"

dcf01 02021 00w02
DTC P2136 Accelerator pedal position (APP) sensor No.1/idle switch voltage correlation problem
• The PCM compares the input voltage from APP sensor No.1 with the input voltage from the idle switch
DETECTION
when the accelerator pedal is released (idle switch is on). If the difference is more than 1.35 V for 0.5 s,
CONDITION
the PCM determines that there is an APP sensor No.1/idle switch angle correlation problem.
• Accelerator pedal misadjustment.
POSSIBLE
CAUSE • Idle switch malfunction
• PCM malfunction
01-028-153

• Is DTC P0122, P0123, P0227 or P0228 (See 01-02B-11 DTC TABLE [WL-C, WE-C].)
present?
• Inspect the APP sensor. (See 01-13B-11 ACCELERATOR PEDAL COMPONENT
(See 01-40B-28 ACCELERATOR PEDAL REMOVAUINSTALLATION [WL-C, WE-C).)
POSITION (APP) SENSOR INSPECTION No Go to the next step.
[WL-C, WE-C].)
(See 01-40B-30 IDLE SWITCH INSPECTION REMOVAUINSTALLATION [WL-C, WE-C).)
[WL-C, WE-C).)
connectors.
(Engine off).

dcf01 02021 00w03
DTC P2143 EGR control solenoid valve control circuit open

• The PCM monitors the EGR control solenoid valve control signal. If the following conditions are detected,
the PCM determines that the EGR control solenoid valve circuit has a malfunction.
DETECTION
- The PCM turns the EGR control solenoid valve off but the voltage remains low (open circuit).
CONDITION
- The PCM internal driver IC temperature is more than 150 °C {320 OF} when the EGR control solenoid
valve is on.
• EGR control solenoid valve malfunction
CAUSE • Open circuit in wiring harness between EGR control solenoid valve (vent) terminal A and main relay
• Open circuit in wiring harness between EGR control solenoid valve (vent) terminal Band PCM terminal 177
• PCM malfunction
01-028-154
MAIN RELAY PCM
EGRCONTROL
SOLENOID VALVE (VENT)
®
@ @ ®
PCM
EGR CONTROL SOLENOID VALVE (VENT)
g.:D)
I~~I
• Verity related service repair information • If the vehicle is not repaired, go to the next step.
the current diagnostic tool. TROUBLESHOOTING [WL-C, WE-C).}
4 INSPECT EGR CONTROL SOLENOID VALVE Yes Repair or replace the terminal, then go to Step 9.
• Disconnect the EGR control solenoid valve
connector.
5 INSPECT EGR CONTROL SOLENOID VALVE Yes Go to the next step.
CONTROL CIRCUIT FOR OPEN CIRCUIT No Repair or replace the wiring harness for a possible open
(Engine off).
• Measure the voltage between EGR control
solenoid valve terminal A (wiring harness-side)
and body ground
01-028-155

6 INSPECT EGR CONTROL SOLENOID VALVE Yes Replace the EGR control solenoid valve, then go to Step 9.
• Inspect the EGR control solenoid valve. (See 01-13B-3INTAKE-AIR SYSTEM REMOVAU
(See 01-16B-6 EGR CONTROL SOLENOID INSTALLATION [WL-C, WE-C].)
VALVE INSPECTION [WL-C, WE-C].) No Go to the next step.
CONTROL CIRCUIT FOR OPEN CIRCUIT No Repair or replace the wiring harness for a possible open
• Inspect for continuity between EGR control
solenoid valve terminal B (wiring harness-side)
connectors.
(Engine off).
tool.
OTC P2144 [WL-C, WE-C)

dcf01 02021 00w04
DTC P2144 EGR control solenoid valve control circuit low input
DETECTION • The PCM monitors the EGR control solenoid valve control signal. If the PCM turns the EGR control
solenoid valve off but the voltage remains low, the PCM determines that the EGR control solenoid valve
CONDITION
circuit has a malfunction (circuit short to ground).
POSSIBLE • Short to ground in wiring harness between EGR control solenoid valve terminal Band PCM terminal 177
• PCM malfunction
01-028-156
MAIN RELAY peM
EGR CONTROL
SOLENOID VALVE
@ ® (j)
PCM
~B~~
I~~ I
AVAILABILITY repair information. -,
4 INSPECT EGR CONTROL SOLENOID VALVE Yes Repair or replace the terminal, then go to Step 8.
connector.
MALFUNCTION No Replace the EGR control solenoid valve, then go to step 8.
• Perform EGR control solenoid valve inspection.
(See 01-168-6 EGR CONTROL SOLENOID
VALVE INSPECTION [WL-C, WE-C].)
• Is EGR control solenoid valve normal?
6 INSPECT EGR CONTROL SOLENOID VALVE Yes Repair or replace the wiring harness for short to ground,
CONTROL CIRCUIT FOR SHORT TO GROUND then go to Step 8.
• Inspect for continuity between EGR control No Go to the next step.
solenoid valve terminal 8 (wiring harness-side)
and body ground.
01-028-157

WE-C].)
connectors.
(Engine off).
tool.

dcf01 02021 OOwOS
DTC P2145 EGR control solenoid valve control circuit high input
"
DETECTION • The PCM monitors the EGR control solenoid valve control signal. If the peM turns the EGR control
solenoid valve on but the voltage still remains high, the PCM determines that the EGR control solenoid
CONDITION
valve circuit has a malfunction (circuit short to power supply).
POSSIBLE • Short to power supply in wiring harness between EGR control solenoid valve terminal Band PCM terminal
177
CAUSE
• PCM malfunction
MAIN RELAY PCM

-< I-
EGR CONTROL
SOLENOID VALVE
@ @ @
---«- ~ 8
(J)
I" //
1//
"
@
EGR CONTROL SOLENOID VALVE PCM

a·:nn
124 123 122 121 120 119 118 117 116 115 114 113 112 111 110 109 108 107 106 105 104 103 102 101
148 147 146 145 144 143 142 141 140 139 138 137 136 135 134 133 132 131 130 129 128 127 126 125
172 171 170 169 168 167 166 165 164 163 162 161160 159 158 157 156 155 154 153 152 151 150 149
196 195 194 193 192 191 190 189 188 187 186 185184 183 182 181 180 179 178 177 176 175 174 173
I~~I I~~I
01-.028-158

CONCERN INTERMITTENT OR CONSTANT? concern exists.
4 INSPECT EGR CONTROL SOLENOID VALVE
CONNECTOR FOR POOR CONNECTION
connector.
5 INSPECT EGR CONTROL SOLENOID VALVE
MALFUNCTION
• Perform EGR control solenoid valve inspection.
(See 01-16B-6 EGR CONTROL SOLENOID
VALVE INSPECTION [WL-C, WE-C].)
• Is the EGR solenoid valve (vent) normal?
CONNECTION
7 INSPECT EGR CONTROL SOLENOID VALVE Yes Repair or replace the wiring harness for short to power
CONTROL CIRCUIT SHORT TO POWER supply, then go to the next step.
SUPPLY No to the next step.
(Engine off).
• Measure the voltage between EGR control
solenoid valve terminal B (wiring harness-side)
and body ground.
connectors.
(Engine off).
tool.
01-028-159

dcf010202100w06
DTC P2146 Fuel injector No.1 and No.4 power supply circuit malfunction
• The PCM monitors the fuel injector No.1 and No.4 power supply voltage when the engine is running. If the
DETECTION
CONDITION
- Fuel injector No.1 and No.4 power supply voltage is less than 43 V
POSSIBLE
• Make sure to reconneCt all disconnected No Go to the next step.
connectors.
(Engine off).

dcf010202100w07
DTC P2147 Fuel injector No.1 and No.4 power supply circuit low input
DETECTION • The PCM monitors the fuel injector No.1 and No.4 power supply current when the engine is running. If the
power supply current is 25 A or above 3 times while other fuel injector power supply current is 25 A or
CONDITION
above, the PCM determines that the fuel injector No.1 and No.4 power supply current is too high.
CAUSE • Short to ground in the wiring harness between the fuel injector No.1 terminal Band PCM terminal 174
• Short to ground in the wiring harness between the fuel injector No.4 terminal Band PCM terminal 150
• PCM malfunction
01-028-160
DTC P2147 Fuel injector No.1 and No.4 power supply circuit low input
FUEL INJECTOR PCM
@ @ (j)
NO.1 @
.----~@
@
NO.4 @
FUEL INJECTOR NO.1, NO.4 PCM

24123 122 121 120 119 118 117 116 115 114 113 112 111 110 109 108 107 106 105 104 103 102 101
48147 146 145 144 143 142 141 140 139 138 137 136 135 134 133 132 131 130 129 128 127 126 125
72171 170 169 168 167 166 165 164 163 162 161 160 159 158 157 156 155 154 153 152 151 150 149
96195 194 193 192 191 190 189 188 187 186 185 184 183 182 181 180179 178 177 176 175 174 173
1 VERIFY FREEZE FRAME DATA HAS BEEN Yes
Go to the next step.
RECORDED NoRecord the FREEZE FRAME DATA on the repair order,
4 INSPECT FUEL INJECTOR CONNECTOR FOR Yes Repair or replace the suspected terminal, then go to Step
POOR CONNECTION 8.
• Turn the engine switch to off. No Go to the next step.
5 INSPECT FUEL INJECTOR CIRCUIT FOR A Yes Repair or replace the wiring harness for a short to ground,
terminals (wiring harness-side) and body
ground.
- Fuel injector No.1 terminal B
01-028-161

6 INSPECT FUEL INJECTOR Yes Replace the fuel injector, then go to Step 8.
7 INSPECT PCM CONNECTOR FOR POOR Yes Repair or replace the suspected terminal, then go to the
CONNECTION next step.
• Inspect for poor connection. (such as
damaged/pulled-out terminals, corrosion).
connectors.
(Engine off).
• Perform the "After Repair. Procedure". (See 01-02B-11 DTC TABLE [WL-C, WE-C].)
PROCEDURE [WL-C, WE-GJ.)

dcf01 02021 00w08
DTC P2148 Fuel injector No.1 and No.4 power supply circuit high input
DETECTION • The PCM monitors the fuel injector No.1 and No.4 power supply current when the engine is running. If the
power supply current is 50 A or above 3 times, the PCM determines that the fuel injector No.1 and No.4
CONDITION
power supply current is too high.
POSSIBLE • Short to power in the wiring harness between the fuel injector No.1 terminal Band PCM terminal 174
CAUSE • Short to power in the wiring harness between the fuel injector No.4 terminal Band PCM terminal 150
• Short to power in the wiring harness between the fuel injector No.1 terminal A and PCM terminal 125
• Short to power in the wiring harness between the fuel injector No.4 terminal A and PCM terminal 126
• PCM malfunction
01-028-162
PCM
FUEL INJECTOR
@ @ (j)
174
NO.1
@ @ (j)
125
@ @ (j)
NO.4 @ @ (j)
FUEL INJECTOR NO.1. NO.4 PCM

1n1n1~1~1~1~1~1E1M1.1~1~1W1W1~1~1~1Y1M
1~1M1M1.1~1~1~1~1W1~1E1E1M1.1~1M1001~1n
"""1
124123122121120119118117116115114113112111110 109 108107106 105
191Q1.1g1«1g1g1M1~1.1~1~1.1.1M1.1.1~1~ 129 1281271
153 152151 1
177 1761751
POOR CONNECTION 8.
• Inspect for poor connection fuel injector for
each cylinder (such as damaged/pulled-out
terminals, corrosion).
01-028-163

5 INSPECT FUEL INJECTORS CIRCUIT FOR Yes Repair or replace the wiring harness for a short to power
SHORT TO POWER SUPPLY supply for the suspected cylinder, then go to Step 8.
(Engine off).
• Inspect the voltage between following terminals
(wiring harness-side) and body ground:
- Fuel injector No.1 terminal 8
- Fuel injector No.4 terminal 8
- Fuel injector No.1 terminal A
- Fuel injector No.4 terminal A
• Inspect the fuel injector. (See 01-148-15 FUEL INJECTOR REMOVAU
(See 01-148-16 FUEL INJECTOR INSTALLATION [WL-C, WE-C].)
7 INSPECT PCM CONNECTOR FOR POOR Yes Repair or replace the suspected terminal, then go the to
CONNECTION Step.
WE-C].)
connectors.
(Engine off).

dcf01 02021 OOW09
DTC P2149 Fuel injector No.2 and No.3 power supply circuit malfunction
• The PCM monitors the fuel injector No.2 and NO.3 power supply voltage when the engine is running. If the
DETECTION
CONDITION
- Fuel injector No.2 and NO.3 power supply voltage is less than 43 V
- Fuel injector No.2 and NO.3 power supply voltage is 53 V or above
POSSIBLE
01-028-164
Intermittent concern exists.

4 VERI TROUBLESHOOTING OF P2149 Yes Replace the PCM, then go to the next step.
• Turn the engine switch off. WE-C].
connectors.
(Engine off).
(See 01-02B-10 AFTER REPAIR No ' Troubleshooting completed.

dcf01 02021 00w1 0
DTC P2150Fuel injector No.2 and No.3 power supply circuit low input
• The PCM monitors the fuel injector No.2 and NO.3 power supply current when the engine is running. If the
DETECTION
power supply current is 25 A or above 3 times while other fuel injector power supply current is 25 A or
CONDITION
above, the PCM determines that the fuel injector No.2 and NO.3 power supply current is too high.
CAUSE • Short to ground in the wiring harness between the fuel injector No.2 terminal A and PCM terminal 102
• Short to ground in the wiring harness between the fuel injector No.3 terminal A and PCM terminal 101
• PCM malfunction
01-028-165
DTC P2150 I Fuel injector No.2 and No.3 power supply circuit low input
FUEL INJECTOR PCM
NO.2
®
DQ@ B
~
@
,-
@ (J)
"
(J)
8
8
~@ @
(3
(J)
J -8 ~ "
NO.3
@ (J)
8
m
124 123 122 121 120 119 118 117 116 115 114 113112 111 110 109 108107 106 105 104 103 102 101
148 147 146 145 144 143 142 141 140 139 138 137136 135 134 133 132131 130 129 128 127 126 125
172171 170 169 168 167 166 165 164 163 162 161 160 159 158 157 156155 154 153 152 151 150 149
196195 194 193 192 191 190 189 188 187 186 185184 183 182 181 180179 178 177 176 175 174 173
I~~ I I~~ I
RECORDED. No Record the FREEZE FRAME DATA on the repair order,
4 INSPECT FUEL INJECTOR CONNECTOR FOR Yes Go to the next step.
POOR CONNECTION No Repair or replace the terminal, then go to Step 8.
5 INSPECT FUEL INJECTORS CIRCUIT FOR Yes Repair or replace the wiring harness for a short to ground,
terminals and body ground.
01-028-166

• Turn the engine switch to off.
• Turn the engine switch off. WE-C].) .
connectors.
(Engine off).

dcf010202100w11
DETECTION • The PCM monitors the fuel injector No.2 and NO.3 power supply current when the engine is running. If the
power supply current is 50 A or above 3 times, the PCM determines that the fuel injector No.2 and NO.3
CONDITION
power supply current is too high.
POSSIBLE • Short to power circuit in the wiring harness between the fuel injector No.2 terminal A and PCM terminal 102
CAUSE • Short to power circuit in the wiring harness between the fuel injector No.3 terminal A and PCM terminal 101
• Short to power in the wiring harness between the fuel injector No.2 terminal Band PCM terminal 149
• Short to power in the wiring harness between the fuel injector No.3 terminal Band PCM terminal 173
• PCM malfunction
01-028-167
PCM
FUEL INJECTOR
@ (j)
@
NO.2 (j)
@ @
@ @ (j)
NO.3
@ @ (j)
A

115114113112111 1101
139 138 137136 135 134 1
01-028-168
POOR CONNECTION 9.
• Inspect for poor connection fuel injector for
each cylinder (such as damaged/pulled-out
terminals, corrosion).
5 INSPECT FUEL INJECTORS CIRCUIT FOR Yes Repair or replace the wiring harness for a short to power
SHORT TO POWER SUPPLY supply for the suspected cylinder, then go to Step 8.
(Engine off).
• Inspect the voltage between following terminals
(wiring harness-side) and body ground:
- Fuel injectors No.2 terminal A
- Fuel injectors No.2 terminal B
- Fuel injectors No.3 terminal A
- Fuel injectors No.3 terminal B
• Inspect the fuel injector. No Go to the next step.
(See 01-14B-16 FUEL INJECTOR
7 INSPECT PCM CONNECTOR FOR POOR Yes Repair or replace the suspected terminal, then go to the
CONNECTION next step.
connectors.
(Engine off).
01-028-169
dcf010202200w01
DTC P2227 BARO sensor circuit range/performance malfunction

• The PCM monitors the input signal from the barometric pressure sensor. If the difference between the
barometric pressure input from the barometric pressure sensor and the boost pressure is more than 11
kPa {O.11 bar, 1.6 psi}, the PCM determines that there is a malfunction in the barometric pressure sensor.
DETECTION
CONDITION Note
• If DTCs P2227 and P0106 are recorded simultaneously, the PCM determines that there is a boost
sensor and barometric pressure sensor characteristic malfunction.
POSSIBLE
CAUSE • BARO sensor (integrated in PCM) malfunction
• Make sure to reconnect all disconnected No No concern is detected. Go to the next step.
connectors.
(Engine off).

dcf010202200w02
DTC P2228 BARO sensor circuit low input
DETECTION • The PCM monitors the input signal for the barometric pressure. If the voltage from the barometric pressure
sensor is less than 2.2 V for 1 s, the PCM determines that there is a malfunction in the barometric
CONDITION
pressure sensor signal system.
POSSIBLE
01-028-170
VERIFY FREEZE FRAME DATA

RECORDED
connectors.
(Engine off).

dcf010202200w03
DTC P2229 BARO sensor circuit high input
DETECTION • The PCM monitors the input signal for the barometric pressure. If the voltage from the barometric pressure
sensor is more than 4.8 V for 1 s, the PCM determines that there is a malfunction in the barometric
CONDITION
pressure sensor signal system.
POSSIBLE
01-028-171

COMPLETED. (See 01-40B-9 PCM REMOVAUINSTALLATION [WL-C,
connectors.
(Engine off).
01-028-172
SYMPTOM TROUBLESHOOTING [WL-C, WE-C]
01-03B SYMPTOM TROUBLESHOOTING [WL-C, WE-C]

SYMPTOM TROU8LESHOOTING NO.13 KNOCKING/PINGING
WIRING DIAGRAM [WL-C, WE-C] .... 01-038-2 [WL-C, WE-C] ..•.•.....•...•..... 01-038-38
SYMPTOM DIAGNOSTIC INDEX N~14POORFUELECONOMY
[WL-C, WE-C] •....•••..........•. 01-038-6 [WL-C, WE-C] ..•.•.••..••••.•..... 01-038-41
SYMPTOM QUICK DIAGNOSIS CHART NO.15 EMISSION COMPLIANCE
[WL-C, WE-C] .•......•••...•••... 01-038-8 [WL-C, WE-C] ...........•••...•.. 01-038-44
NO.1 MELTING OF MAIN OR OTHER NO.16 HIGH OIL CONSUMPTION/
FUSES [WL-C, WE-C] ......•...... 01-038-14 LEAKAGE [WL-C, WE-C] .•...•..... 01-038-47
NO.2 ENGINE CHECK LAMP NO.17 COOLING SYSTEM CONCERNS-
ILLUMINATES [WL-C, WE-C] .•....• 01-038-15 OVERHEATING [WL-C, WE-C] ....... 01-038-48
NO.3 WILL NOT CRANK [WL-C, WE-C] 01-038-15 NO.18 COOLING SYSTEM
NO.4 HARD START/LONG CRANK/ CONCERNS-RUNS COLD
ERRATIC START/ERRATIC [WL-C, WE-C] ••.•....•........... 01-038-50
CRANK [WL-C, WE-C] .••....••••.. 01-038-17 NO.19 EXCESSIVE 8LACKSMOKE
NO.5 ENGINE STALLS-AFTER START/ [WL-C, WE-C] ...........•........ 01-038-50
AT IDLE [WL-C, WE-C] ....••••.•... 01-038-19 NO.20 FUEL ODOR (IN ENGINE
NO.6 CRANKS NORMALLY BUT COMPARTMENT) [WL-C, WE-C] ..•.. 01-038-53
WILL NOT START [WL-C, WE-C] ..... 01-038-22 NO.21 ENGINE NOISE [WL-C, WE-C] •.. 01-038-54
NO.7 SLOW RETURN TO IDLE NO.22 VI8RATION CONCERNS
[WL-C, WE-C] ...•.••.••........•. 01-038-24 (ENGINE) [WL-C, WE-C] ..•.......•. 01-038-56
NO.8 ENGINE RUNS ROUGH/ NO.23 AlC DOES NOT WORK
ROLLING IDLE [WL-C, WE-C] ....... 01-038-26 SUFFICIENTLY [WL-C, WE-C] ...••... 01-038-57
NO.9 FAST IDLE/RUNS ON NO.24 AlC ALWAYS ON OR AlC
[WL-C, WE-C] •..•.......•••..•... 01-038-28 COMPRESSOR RUNS
NO.10 LOW IDLE/STALLS DURING CONTINUOUSLY
DECELERATION [WL-C, WE-C] .•.•.• 01-038-30 [WL-C, WE-C] ...•......•......... 01-038-59
NO.11 ENGINE STALLS/QUITS, NO.25 AlC DOES NOT CUT OFF
ENGINE RUNS ROUGH, MISSES, UNDER WIDE OPEN THROTTLE
8UCK/JERK, HESITATION/STUM8LE, CONDITIONS [WL-C, WE-C] ......•.. 01-038-59
SURGES [WL-C, WE-C] ......•.••.. 01-038-32 INTERMITTENT CONCERN
NO.12 LACK/LOSS OF TROU8LESHOOTING
POWER-ACCELERATION/CRUISE [WL-C, WE-C] ......•....•••...... 01-038-60
[WL-C, WE-C] ....•......•.•...... 01-038-35 ENGINE CONTROL SYSTEM OPERATION
INSPECTION [WL-C, WE-C] •....•..• 01-038-62
01-038-1
SYMPTOM TROUBLESHOOTING WIRING DIAGRAM [WL-C, WE-C]
dcf010300000w27
r-----~Y'~------~D
.j--f---{E
STA DLC
IG-
FEN
KLN
TEN
F
DLC-2
KLN
' - - - - - I TEN
PCM
(BUILT INTO
GLOW INDICATOR
LIGHT ~-+------I-----------{
BARO SENSOR)
VEHICLE
SPEED SIGNAL
FUEL
INJECTOR
FUEL
INJECTOR
NO.3
FUEL
INJECTOR
NO.2
FUEL
INJECTOR
IAT NO.1
SENSOR
NO.2
DBG 102BWBY01
01-038-2
C
j- ------- -------WITH RFW-
RFWLOCK
SOLENOID
APP )--+-+.1' VALVE
SENSOR
RFW FREE
SOLENOID
)-_-+.1' VALVE
FUEL PRESSURE
SENSOR
BOOST
SENSOR
CMP SENSOR
ECT
SENSOR LL-1-1----\.
FUEL CKPSENSOR
TEMPERATURE
SENSOR
EGRVALVE
POSITION
SENSOR PCM
11---+--0 o---+--+-... GLOW

BLOWER L...-_-I
PLUG
RELAY
MOTOR
REFRIGERANT
PRESSURE - ---------------------------.
~~-;-~ o-~~~ CONTROL ,
SOLENOID VALVE :
AlC
COMPRESSOR
AlC RELAY
AlC
:SWITCH
,
THERMO SWITCH
'- - - - - - - - - - - - - - - • WITH AlC· - - - - - - - - - - - - - - - ~
DBG102BWBY02
01-038-3
~-+------(E
DLC
IG-
FEN
KLN
TEN
F
DLC-2
'-----;KLN
'-----lTEN
PCM
(BUILT INTO
GLOW INDICATOR
BARO SENSOR)
LIGHT ~-+------I---------{
VEHICLE
SPEED SIGNAL
FUEL
INJECTOR
FUEL
INJECTOR
NO.3
FUEL
INJECTOR
NO.2
FUEL
INJECTOR
IAT NO.1
SENSOR
NO.2
DBG102BWBY03
01-038-4
RFWLOCK
SOLENOID
APP I--+-I-.r' VALVE
SENSOR
FUEL PRESSURE
SENSOR
BOOST
SENSOR
CMPSENSOR
ECT
SENSOR ~I--__--(
FUEL CKPSENSOR
TEMPERATURE
SENSOR
EGRVALVE
POSITION
SENSOR PCM
I1-+--o o--+-+-.... GLOW

BLOWER L...-_----' PLUG
RELAY
MOTOR
EGR CONTROL
SOLENOID VALVE
REFRIGERANT
PRESSURE - ---------------------------1
~~--~ O--~~~ CONTROL ,
SOLENOID VALVE :
AlC
COMPRESSOR
AlC RELAY
AlC
:SWITCH
THERMO SWITCH
,
'- - - - - - - - - - - - - - - • WITH AlC· - - - - - - - - - - - - - - -
DBG102BWBY02
01-038-5
SYMPTOM DIAGNOSTIC INDEX [WL-C, WE-C]
dcf010300000w28
No. TROUBLESHOOTING ITEM DESCRIPTION PAGE

(See 01-038-14 NO.1
MELTING OF MAIN OR
1 Melting of main or other fuses - OTHER FUSES [WL-C, WE-
C).)
(See 01-038-15 NO.2 ENGINE
2 Engine check lamp illuminates Engine check lamp is illuminated incorrectly. CHECK LAMP ILLUMINATES
[WL-C, WE-C).)
(See 01-038-15 NO.3 WILL
3 Will not crank Starter does not work.
NOT CRANK [WL-C, WE-C).)
(See 01-038-17 NO.4 HARD
Starter cranks engine at normal speed but
Hard start!long crank/erratic start! START/LONG CRANK/
4 engine requires excessive cranking time
erratic crank ERRATIC START/ERRATIC
before starting.
CRANK [WL-C, WE-C].)
(See 01-038-19 NO.5 ENGINE
Engine stops unexpectedly at idle and/or
5 Engine stalls After start!at idle STALLS-AFTER START/AT
after start.
IDLE [WL-C, WE-C).)
(See 01-038-22 NO.6
Starter cranks engine at normal speed but CRANKS NORMALLY BUT
6 Cranks normally but will not start
engine will not run. WILL NOT START [WL-C, WE-
C).)
(See 01-038-24 NO.7 SLOW
Engine takes more time than normal to
7 Slow return to idle RETURN TO IDLE [WL-C, WE-
return to idle speed.
C).)
Engine speed fluctuates between specified (See 01-038-26 NO.8 ENGINE
8 Engine runs rough/rolling idle idle speed and lower speed and engine RUNS ROUGH/ROLLING
shakes excessively. IDLE [WL-C, WE-C].)
Engine speed continues at fast idle after
(See 01-038-28 NO.9 FAST
warm-up.
9 Fast idle/runs on IDLE/RUNS ON [WL-C, WE-
Engine runs after engine switch is turned to
C).)
OFF.
(See 01-038-30 NO.10 LOW
Engine stops unexpectedly at beginning of IDLE/STALLS DURING
10 Low idle/stalls during deceleration
deceleration or recovery from deceleration. DECELERATION [WL-C, WE-
C).)
Engine stops unexpectedly at beginning of
Acceleration/
Engine stalls/quits acceleration or during acceleration.
cruise
Engine stops unexpectedly while cruising.
Acceleration/ Engine speed fluctuates during acceleration
Engine runs rough
cruise or cruising.
(See 01-038-32 NO.11
Acceleration/ Engine misses during acceleration or ENGINE STALLS/QUITS,
Misses
cruise cruising. ENGINE RUNS ROUGH,
11
Acceleration/ MISSES, 8UCK/JERK,
Vehicle bucks/jerks during acceleration, HESITATION/STUM8LE,
8uck/jerk cruise/
cruising, or deceleration. SURGES [WL-C, WE-C].)
deceleration
Momentary pause at beginning of
Hesitation/stumble Acceleration
acceleration or during acceleration.
Acceleration/ Momentary minor irregularity in engine
Surges
cruise output.
(See 01-038-35 NO.12 LACK/
Acceleration/ Performance is poor under load (e.g. power LOSS OF POWER-
12 Lack/loss of power
cruise down when climbing hills). ACCELERATION/CRUISE
[WL-C, WE-C).)
(See 01-038-38 NO.13
Excessive shrilly knocking sound from
13 Knocking/pinging KNOCKING/PINGING [WL-C,
engine.
WE-C].)
(See 01-038-41 NO.14 POOR
14 Poor fuel economy Fuel economy is unsatisfactory. FUEL ECONOMY [WL-C, WE-
C).)
(See 01-038-44 NO.15
15 Emissions compliance Fails emissions test. EMISSION COMPLIANCE
[WL-C, WE-C].)
01-038-6

(See 01-03B-47 NO.16 HIGH
16 High oil consumption/leakage Oil consumption is excessive. OIL CONSUMPTION/
LEAKAGE [WL-C, WE-C].)
(See 01-03B-48 NO.17
Cooling system Engine runs at higher than normal COOLING SYSTEM
17 Overheating
concerns temperature/overheats. CONCERNS-OVERHEATING
[WL-C, WE-C].)
(See 01-03B-50 NO.18
Cooling system Engine does not reach normal operating COOLING SYSTEM
18 Runs cold
concerns temperature. CONCERNS-RUNS COLD
[WL-C, WE-C].)
(See 01-03B-50 NO.19
Excessive black smoke is observed in
19 Excessive black smoke EXCESSIVE BLACK SMOKE
exhaust gas.
[WL-C, WE-C].)
(See 01-03B-53 NO.20 FUEL
ODOR (IN ENGINE
20 Fuel odor (in engine compartment) Fuel smell or visible leakage.
COMPARTMENT) [WL-C, WE-
C].)
(See 01-03B-54 NO.21
21 Engine noise Engine noise from under hood. ENGINE NOISE [WL-C, WE-
C].)
(See 01-03B-56 NO.22
22 Vibration concerns (engine) Vibration from under hood or driveline. VIBRATION CONCERNS
(ENGINE) [WL-C, WE-C).)
(See 01-03B-57 NO.23 AlC
AlC compressor magnetic clutch does not DOES NOT WORK
23 AlC does not work sufficiently
engage when AlC is turned on. SUFFICIENTLY [WL-C, WE-
C).)
(See 01-03B-59 NO.24 AlC
ALWAYS ON OR AlC
AlC always on or AlC compressor runs AlC compressor magnetic clutch does not
24 COMPRESSOR RUNS
continuously disengage.
CONTINUOUSLY [WL-C, WE-
C).)
(See 01-03B-59 NO.25 AlC
AlC does not cut off under wide open AlC compressor magnetic clutch does not DOES NOT CUT OFF UNDER
25
throttle conditions disengage under wide open throttle. WIDE OPEN THROTTLE
CONDITIONS [WL-C, WE-C].)
01-038-7
SYMPTOM QUICK DIAGNOSIS CHART [WL-C, WE-C]
dcf010300000w29
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2 Engine check lamp illuminates
3 Will not crank x x x x x x
4 Hard start/long crank/erratic start/erratic crank x x x x
5 Engine stalls After start/at idle x x
6 Cranks normally but will not start x x
7 Slow return to idle
8 Engine runs rough/rolling idle x x
9 Fast idle/runs on x
10 Low idle/stalls during deceleration x x
Engine stalls/quits Acceleration/cruise x x
Engine runs rough Acceleration/cruise x x
Misses Acceleration/cruise x x
11
Buck/jerk Acceleration/cruise/deceleration x x
Hesitation/stumble Acceleration x x
Surges Acceleration/cruise x x
12 Lack/loss of power Acceleration/cruise x x
13 Knocking/pinging x x
14 Poor fuel economy x x
15 Emissions compliance x x x
16 High oil consumption/leakage x x x x
17 Cooling system concerns Overheating x x
18 Cooling system concerns Runs cold
19 Excessive black smoke x x x
20 Fuel odor (in engine compartment)
21 Engine noise x x x x
22 Vibration concerns (engine) x x x
24 AlC always on or AlC compressor runs continuously
25 AlC does not cut off under wide open throttle conditions
01-038-8
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3 Will not crank
4 Hard start/long crank/erratic start/erratic crank x x x x
5 Engine stalls After start/at idle x x x
6 Cranks normally but will not start x x
7 Slow return to idle x "
8 Engine runs rough/rolling idle x x x x

9 Fast idlelruns on
10 Low idle/stalls during deceleration x x
Engine stalls/quits Acceleration/cruise x x x x x
Engine runs rough Acceleration/cruise x x x x x
Misses Acceleration/cruise x x x x x
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Hesitation/stumble Acceleration x x x x x
Surges Acceleration/cruise x x x x x
12 Lack/loss of power Acceleration/cruise x x x x x x
13 Knocking/pinging x x x x
14 Poor fuel economy x x x x x
15 Emissions compliance x x x x x x
16 High oil consumption/leakage
17 Cooling system concerns Overheating x x x x
18 Cooling system concerns Runs cold x x
19 Excessive black smoke x x x x
20 Fuel odor (in engine compartment)
22 Vibration concerns (engine) x x x x x x
01-038-9
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5 Engine stalls After start/at idle x x x x x x x x
6 Cranks normally but will not start x x x x x x x x
7 Slow return to idle x x x x x x x
8 Engine runs rough/rolling idle x x x x x x x x x
9 Fast idle/runs on
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Surges Acceleration/cruise x x x x x x x x x
12 Lack/loss of power Acceleration/cruise x x x x x x x x x x x
13 Knocking/pinging x x x x x x x x x
14 Poor fuel economy x x x x x x x x x x
15 Emissions compliance x x x x x x x x x x x x
16 High oil consumption/leakage x
17 Cooling system concerns Overheating
19 Excessive black smoke x x x x x x x x x x
20 Fuel odor (in engine compartment) x
22 Vibration concerns (engine) x x x x
01-038-10
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3 Will not crank
4 Hard start/long crank/erratic start/erratic crank x x x x x x x x
5 Engine stalls After start/at idle x x x x x x x x x
6 Cranks normally but will not start x x x x x x x x
7 Slow return to idle x x x
8 Engine runs rough/rolling idle x x x x x x x x x
10 Low idle/stalls during deceleration x x x x x x x
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Engine runs rough Acceleration/cruise x x x x x x x x x
Misses Acceleration/cruise x x x x x x x X x
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Hesitation/stumble Acceleration x x x x x x x x x
Surges Acceleration/cruise x x x x x x x x x
12 Lack/loss of power Acceleration/cruise x x x x x x x x x
13 Knocking/pinging x x x x x
14 Poor fuel economy x x x x x x x x
15 Emissions compliance x x x x x x x x
17 Cooling system concerns Overheating
22 Vibration concerns (engine) x x x x
01-038-11
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3 Will not crank
4 Hard start/long crank/erratic start/erratic crank x x x x x
5 Engine stalls After start/at idle x x x x x x
6 Cranks normally but will not start x x x
7 Slow return to idle x x x
8 Engine runs rough/rolling idle x x x x x x
10 Low idle/stalls during deceleration x x x x x
Engine stalls/quits Acceleration/cruise x x x x x
Engine runs rough Acceleration/cruise x x x x x x
Misses Acceleration/cruise x x x x x x
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Hesitation/stumble Acceleration x x x x x x x x
Surges Acceleration/cruise x x x x x x x x
12 Lack/loss of power Acceleration/cruise x x x x x x x x
13 Knocking/pinging x x x x x x
14 Poor fuel economy x x x x x x x
15 Emissions compliance x x x x x x
17 Cooling system concerns Overheating x
21 Engine noise x x x x x x
22 Vibration concerns (engine) x x x x x
23 AlC does not work sufficiently x
25 AlC does not cut off under wide open throttle conditions x x
01-038-12
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01-038-13
NO.1 MELTING OF MAIN OR OTHER FUSES [WL-C, WE-C]
dcf010300000w30
1 MELTING OF MAIN OR OTHER FUSES

[TROUBLESHOOTING HINTS]
Inspect condition of fuse.
Shorted wiring harness Deterioration
.n. Fuse
.fi.
Repair shorted wiring harness and replace fuse Replace fuse
Damaged fuse Related wiring harness

MAIN MAIN fuse
• BTN1 fuse
- Room fuse
-DLC-2
• IGKEY2fuse
- Engine switch
-PCM
- Starter
• Generator
IGKEY1 IGKEY1 fuse
• Engine switch
• METER fuse
• ENGINE fuse
-DLC
-PCM
IGKEY2 IGN 2 fuse
• Engine switch
-PCM
- Starter
BTN1 BTN1 fuse
• ROOM fuse
-DLC-2
INJ/FIP INJ/FIP fuse
• Generator
• Main relay
-PCM
- Glow plug relay
- MAF sensor/lAT sensor No.2
- Intake shutter solenoid valve (full)
- Intake shutter solenoid valve (half)
- Fuel metering valve
- Variable swirl control solenoid valve *1
- EGR solenoid valve
- EGR control solenoid valve
- VBC solenoid valve
- Lock solenoid
ROOM ROOM fuse
• DLC-2
ENGINE ENGINE fuse
• DLC
• PCM
METER METER fuse
• DLC
01-038-14
Damaged fuse Related wiring harness

GLOW GLOW fuse
• Glow plug relay
-Glow plug
*1
: With variable swirl system
NO.2 ENGINE CHECK LAMP ILLUMINATES [WL-C, WE-C]
2 ENGINE CHECK LAMP ILLUMINATES

DESCRIPTION • Engine check lamp illuminates incorrectly.
POSSIBLE • PCM illuminates for emission-related concern (DTC is stored in PCM).
CAUSE • Instrument cluster malfunction.
STEP INSPECTION RESULTS ACTION
Connect the current diagnostic tool to the DLC- Yes DTC is displayed:
2. • Go to the appropriate DTC test.
Turn the engine switch to the ON position (See 01-02B-11 DTC TABLE [WL-C, WE-C].)
(Engine off). No No DTC is displayed:
Retrieve any DTCs. • Inspect the instrument cluster operation.
Are any DTCs displayed?
2 Verify test results.
• If normal, return to the diagnostic index to service any additional symptoms.
(See 01-03B-6 SYMPTOM DIAGNOSTIC INDEX [WL-C, WE-C].)
• If the malfunction remains, inspect the related Service Information and perform repair or diagnosis.
- If the vehicle is repaired, troubleshooting completed.
- If the vehicle is not repaired or additional diagnostic information is not available, reprogram the PCM if later
calibration is available. Retest.
NO.3 WILL NOT CRANK [WL-C, WE-C]

dcf01030000Ow32
3 WILL NOT CRANK

DESCRIPTION • Starter does not work.
• Open starter circuit between engine switch and starter
• Starter malfunction
POSSIBLE • Seized/hydrolocked engine, dual-mass flywheel
CAUSE • Immobilizer system and/or circuit malfunction (if equipped)
• Immobilizer system operating properly (engine key is not registered)
• Low or dead battery
• Charging system malfunction
1 Note Yes Both conditions appear:
• The following test should be perform for Go to Step 4.
vehicles with immobilizer system. Go to No Either or other condition appears:
Step 10 for vehicles without immobilizer Go to the next step.
system.
Connect the current diagnostic tool to the DLC-

2.
Do following conditions appear?
• Engine is not completely started.
• DTC P1260 is displayed.
2 Is the coil connector securely connected to coil? Yes Go to the next step.
No Connect the coil connector securely.
Return to Step 1.
3 Does the security light illuminate? Yes Go to the next step.
No Inspect the instrument cluster and wiring harness.
01-038-15

4 Connect the current diagnostic tool to the DLC-2 Yes Go to the appropriate DTC test.
and retrieve the any DTCs. No Go to the next step.
DTC
P1259, P1260, P1602, P1603, P1621, P1622,
P1623,P1624
5 Is there continuity between PCM ground Yes Go to the next step.
terminals 202, 204, 206 and ground? No Repair or replace wiring harness.
6 Turn the engine switch to the ON position Yes Go to the next step.
(Engine off). No Repair or replace wiring harness.
Access the VPWR PID.
Is the VPWR PID normal?
Specification
Battery voltage
7 Inspect the following wiring harnesses and Yes Repair or replace malfunctioning part.
• Between immobilizer unit terminal F and coil
terminal A
• Between immobilizer unit terminal D and coil
terminal C
Is there any malfunction (open or short circuit,
terminal corrosion, etc.)?
8 Inspect the following: Yes Go to the next step.
• Battery connection No Service if necessary.
• Battery condition Repeat Step 12.
• Fuses
Are all items normal?
9 Is the clicking sound heard from starter when Yes Go to Step 11.
engine switch is turned to START? No Go to the next step.
10 Inspect the starting system. Yes Inspect for seized/hydro locked engine, dual-mass
Is the starting system normal? flywheel.
No Repair or replace components as required.
11 Do any other electrical accessories work? Yes Go to the next step.
No Inspect the charging system.
12 Connect the current diagnostic tool to the DLC- Yes DTC is displayed:
2. Go to the appropriate DTC test.
Turn the engine switch to the ON position Communication error message is displayed:
(Engine off). inspect the following:
Retrieve the any DTCs. • Open circuit between main relay and PCM terminal
Are any DTC displayed? 201,203,205
• Open circuit main relay and PCM terminal 219
• Main relay stuck open
• Open or poor ground circuit (PCM terminal 202,
204,206)
• Poor connection vehicle body ground
No No DTC is displayed:
inspect the following:
• START circuit in engine switch
• Open circuit between engine switch and starter
- If the vehicle is repaired, the troubleshooting completed.
01-038-16
NO.4 HARD START/LONG CRANK/ERRATIC START/ERRATIC CRANK [WL-C, WE-C]
dcf010300000w33
4 HARD START/LONG CRANK/ERRATIC START/ERRATIC CRANK

• Starter cranks engine at the normal speed but the engine requires excessive cranking time before
DESCRIPTION starting.
• Battery is in normal condition.
• Poor fuel quality
• Intake-air system restriction or clogging
• Starting system malfunction
• Inadequate fuel pressure
• Fuel pressure limiter malfunction (built-in common rail)
• Engine overheating
• Glow system malfunction
• Fuel filter clogging or restriction
• Fuel line clogging or restriction
• Fuel leakage
• Exhaust system and/or oxidation catalytic converter restriction or clogging
• Incorrect fuel injection timing
• Erratic signal from CKP sensor
• Erratic signal from CMP sensor
• ECT sensor or related circuit malfunction
POSSIBLE
• Accelerator pedal position (APP) sensor or related circuit malfunction
CAUSE
• MAF sensor/IAT sensor No.2 or related circuit malfunction
• Fuel pressure sensor or related circuit malfunction
• Low engine compression
• EGR system malfunction
Warning
The following troubleshooting flow chart contains the fuel system diagnosis and repair
procedures. Read the following warnings before performing the fuel system services:
• Fuel vapor is hazardous. It can easily ignite, causing serious injury and damage. Always keep
sparks and flames away from fuel.
• Fuel line spills and leakage are dangerous. Fuel can ignite and cause serious injury or death
and damage. Fuel can also irritate skin and eyes. To prevent this, always complete "BEFORE
REPAIR PROCEDURE" and "AFTER REPAIR PROCEDURE" described in this manual.
Diagnostic Procedure
• Fuel quality (e.g.: include water No Service if necessary.
contamination, winter/summer blend) Repeat Step 1.
• Fuel line/fuel filter clogging
• Intake-air system restriction
2 Is the engine overheating? Yes Go to the symptom troubleshooting "NO.17 COOLING
SYSTEM CONCERNS-OVERHEATING [WL-C, WE-
C]".
(Engine off). Communication error message is displayed:
Retrieve any DTCs. Inspect the following:
Are any DTCs displayed? • Open circuit between main relay and PCM terminal
201,203,205
204,206)
• Poor connection to vehicle body ground
01-038-17

4 Does the engine start normally after warm-up? Yes Inspect the glow system operation.
(See 01-138-9 GLOW PLUG RELAY INSPECTION
[WL-C, WE-C].)
io" '
Replace any malfunctioning part if necessary.
If the glow system is normal, go to the next step.
5 Is there any restriction in the exhaust system or Yes Repair or replace if necessary.
oxidation catalytic converter? No Go to the next step.
6 Inspect for fuel leakage from the fuel pipe. Yes Repair or replace if necessary.
Is any fuel leakage found on the fuel pipe? No Go to the next step.
7 Inspect the APP sensor. Yes Go to the next step.
(See 01-408-28 ACCELERATOR PEDAL No Replace the accelerator pedal component.
POSITION (APP) SENSOR INSPECTION [WL-
C, WE-C].)
Is the APP sensor normal?
8 Inspect the CKP sensor. Yes Go to the next step.
(See 01-408-39 CRANKSHAFT POSITION No Replace the CKP sensor.
(CKP) SENSOR INSPECTION [WL-C, WE-C].) Then go to the next step.
(See 01-408-38 CRANKSHAFT POSITION
(CKP) SENSOR REMOVAUINSTALLATION
[WL-C, WE-C].)
Is the CKP sensor normal?
9 Visually inspect the CMP sensor and teeth of Yes Inspect following PIDs:
pulse wheel. (See 01-408-10 PCM INSPECTION [WL-C, WE-C].)
Are CMP sensor and teeth of pulse wheel • ECT
normal? • IAT
• MAF
• RPM
If the PID value is not as specified, repair or replace
the malfunctioning parts.
If the PID value is normal, go to the next step.
No Replace malfunctioning parts.
10 Inspect fuel pressure sensor. Yes Go to the next step.
(See 01-408-33 FUEL PRESSURE SENSOR No Replace common rail.
Is fuel pressure normal?
11 Is engine compression correct? Yes Go to the next step.
(See 01-108-6 COMPRESSION INSPECTION No Inspect the following:
[WL-C, WE-C].)
• Damaged valve seat
• Worn valve stem and valve guide
• Worn or stuck piston ring
• Worn piston, piston ring or cylinder
Service if necessary.
12 Inspect fuel injector. Yes Go to the next step.
(See 01-148-16 FUEL INJECTOR INSPECTION No Repair or replace if necessary.
[WL-C, WE-C).) (See 01-148-15 FUEL INJECTOR REMOVAU
Is fuel injector normal? INSTALLATION [WL-C, WE-C).)
13 Inspect the EGR system operation. Yes Go to the next step.
Is the EGR system operation normal? No Repair or replace the malfunctioning part according to
the EGR system operation results.
14 Inspect starting system. Yes Inspect for loose connectors or poor terminal contact.
Is the starting system normal? If normal, remove and inspect supply pump and
common rail.
No Repair or replace components as required.
• If normal, return to the diagnostic index to service any additional symptoms .
(See 01-038-6 SYMPTOM DIAGNOSTIC INDEX [WL-C, WE-C].)
• If the malfunction remains, inspect the related Service Information and perform repair or diagnosis .
01-038-18
NO.5 ENGINE STALLS-AFTER START/AT IDLE [WL-C, WE-C]
dcf010300000w34
5 ENGINE STALLS-AFTER START/AT IDLE

DESCRIPTION • Engine stops unexpectedly.
• AlC system improper operation
• Immobilizer system and/or circuit malfunction (if equipped)
• Fuel pressure sensor related circuit malfunction
• Fuel leakage
POSSIBLE
CAUSE
• Exhaust system and/or catalyst converter restriction or clogging
• V-reference voltage supply circuit malfunction
Warning
sparks and flames away from fuel. .
•The following test should be perform for Go to Step 4.
system.
Connect the current diagnostic tool to the DLC-

2.
• Engine is not completely started .
• DTC P1260 is displayed .
Return to Step 1.
4 Connect the current diagnostic tool to the DLC-2 Yes Go to the appropriate DTC test.
and retrieve the any DTCs. No Go to the next step.
DTC
P1259,P1260,P1602, P1603,P1621, P1622,
P1623,P1624
01-038-19

6 Turn the engine switch to the ON position Yes Go to the next step.
(Engine off). No Repair or replace wiring harness.
Access the VPWR PID.
Is the VPWR PID normal?
Specification
Battery voltage
7 Inspect the following wiring harnesses and Yes Repair or replace malfunctioning part.
• Between immobilizer unit terminal F and coil
terminal A
• Between immobilizer unit terminal 0 and coil
terminal C
Is there any malfunction (open or short circuit,
terminal corrosion, etc.)?
• Fuel quality (e.g.: include water No Service if necessary.
9 Is the engine overheating? Yes Go to symptom troubleshooting "NO.17 COOLING
C]".
10 Note Yes Go to the next step.
• Ignore DTC P0122, P0123, P0222 or No Inspect the open or short circuit for wiring harness.
P0223 while performing this test. • Between PCM terminal 213 and APP sensor
terminal A
Disconnect the APP sensor connector.
Measure the voltage at the APP sensor
connector the VREF terminal (terminal A) with
the engine switch to the ON position.
Specification
4.5-5.5 V
Is the voltage normal?
Turn the engine switch to the ON position Communication error message is displayed:
(Engine off). Inspect the following:
Retrieve the any DTCs. • Open circuit between main relay and PCM terminal
Are any DTC displayed? 201,203,205
204,206)
• Poor connection vehicle body ground
.Go to the next step.
12 Does the engine start normally after warm-up? Yes Inspect the glow system operation.
(See 01-13B-9 GLOW PLUG RELAY INSPECTION
[WL-C, WE-C].)
13 Is there any restriction in the exhaust system or Yes Repair or replace if necessary.
the catalyst converter? No Go to the next step.
14 Access the RPM PID. Yes Go to the next step.
Is the RPM PID indicating engine speed during No Go to Step 17.
cranking engine?
01-038-20

• The following test should be performed on No AlC is always on:
the vehicles with AlC system. If the Go to symptom troubleshpoting "NO.24 AlC ALWAYS
following test cannot be performed due to ON OR AlC COMPRESSOR RUNS CONTINUOUSLY
engine stalling, go to the next step. [WL-C, WE-C]".
• Go to the next step for the vehicle without Other symptoms:
AlC system. Inspect following:
• Refrigerant charging amount
Connect the pressure gauge to the AlC line. • Cooling fan No.1 and/or cooling fan No.2 operation
Turn the blower and the AlC switches on.
Is the pressure within specifications?
16 Inspect the adjustment of the APP sensor. Yes Go to the next step.
(See 01-40B-28 ACCELERATOR PEDAL No Adjust APP sensor correctly.
C, WE-C].)
Are APP sensor adjusted correctly?
17 Depress the accelerator pedal slightly. Yes Inspect the idle speed.
Crank engine. (See 01-10B-22 Idle Speed Inspection.)
Does the engine start now? No Go to the next step.
18 Inspect for fuel leakage from fuel pipe. Yes Repair or replace if necessary.
Is any fuel leakage found on fuel pipe? No Go to the next step.
(See 01-40B-39 CRANKSHAFT POSITION No Replace the CKP sensor.
(See 01-40B-38 CRANKSHAFT POSITION
[WL-C, WE-C].)
20 Visually inspect the CMP sensor and teeth of the Yes Inspect following PIDs:
pulse wheel. (See 01-40B-10 PCM INSPECTION [WL-C, WE-C].)
Are the CMP sensor and teeth of pulse wheel • ECT
normal? • IAT
• MAF
• RPM
malfunctioning parts.
21 Inspect the fuel pressure sensor. Yes Go to the next step.
(See 01-40B-33 FUEL PRESSURE SENSOR No Replace common rail.
Is the fuel pressure normal?
22 Is the engine compression correct? Yes Go to the next step.
(See 01-10B-6 COMPRESSION INSPECTION No Inspect the following:
[WL-C, WE-C].) • Damaged valve seat
23 Inspect the fuel injector. Yes Go to the next step.
(See 01-14B-16 FUEL INJECTOR INSPECTION No Repair or replace if necessary.
[WL-C, WE-C].)
Is the fuel injector normal?
Is the EGR system operation normal? No Repair or replace malfunctioning part according to
EGR system operation results.
01-038-21
NO.6 CRANKS NORMALLY BUT WILL NOT START [WL-C, WE-C]
dcfO 10300000w35
6 CRANKS NORMALLY BUT WILL NOT START

• Starter cranks engine at normal speed but engine will not run.
DESCRIPTION • Refer to symptom troubleshooting "NO.5 Engine stalls" if this symptom appears after engine stall.
• Fuel is in fuel tank.
• Battery is in normal condition.
• Fuel line restriction
• Fuel leakage
• Fuel filter clogging
• V-reference supply circuit malfunction
POSSIBLE • ECT sensor or related circuit malfunction
CAUSE • Supply pump malfunction
• Immobilizer system and/or circuit malfunction (if equipped)
• Main repay malfunction
Warning
• The following test should be perform for Go to Step 4.
system.
Connect the current diagnostic tool to the OLC-

2.
• Engine is not completely started .
• OTC P1260 is displayed .
Return to Step 1.
4 Connect the current diagnostic tool to the OLC-2 Yes Go to the appropriate OTC test.
and retrieve the any OTCs. No Go to the next step.
DTC
P1259, P1260, P1602, P1603, P1621, P1622,
P1623,P1624
01-038-22

(See 01-408-33 FUEL PRESSURE SENSOR No Replace the common rail.
[WL-C, WE-CJ.) • Damaged valve seat
[WL-C, WE-CJ.)
Is the fuel injector normal?
18 Inspect the EGR system operation. Yes Remove and inspect the supply pump and common
Is the EGR system operation normal? rail.
No Repair or replace malfunctioning part according to
(See 01-038-6 SYMPTOM DIAGNOSTIC INDEX [WL-C, WE-CJ.)
• If malfunction remains, inspect the related Service Information and perform repair or diagnosis .
NO.7 SLOW RETURN TO IDLE [WL-C, WE-C]

dcf010300000w36
7 SLOW RETURN TO IDLE
DESCRIPTION • Engine takes more time than normal to return to idle speed.
• Engine speed continues at fast idle after warm-up.
• Thermostat is stuck open
• Fuel injection timing is incorrect
• MAF sensor/lAT sensor No.2 or related circuit malfunction
• Incorrect idle speed
• Excessive fuel pressure
POSSIBLE • Supply pump malfunction
CAUSE • Fuel pressure limiter malfunction (built-in common rail)
• Fuel injector malfunction (incorrect fuel regulate pressure)
• AlC system malfunction
Warning
01-038-24
1 Connect the current diagnostic tool to the DLC- Yes OTC is displayed:
Turn the engine switch to the ON position (See 01-028-11 DTC TA8LE [WL-C, WE-C].)
Retrieve any DTCs. Inspect the following: .
201,203,205
204,206)
No No OTC is displayed:
2 Access ECT PID. Yes Go to the next step.
Start and warm-up the engine to normal No ECT PIO is higher than 112°C {233 OF}:
operating temperature. Go to the symptom troubleshooting "NO.17 COOLING
Is the ECT PID reading between 82-112 °C SYSTEM CONCERNS-OVERHEATING [WL-C, WE-
{180-233 OF}? C]".
ECT PIO is less than 82°C {180 OF}:
Go to the symptom troubleshooting "NO.18 COOLING
SYSTEM CONCERNS-RUNS COLD [WL-C, WE-C]".
3 Inspect the idle speed. Yes Go to the next step.
(See 01-108-21 ENGINE TUNE-UP [WL-C, WE- No Repair or replace malfunctioning part according to idle
C].) speed inspection results.
Is the idle speed correct?
4 Inspect the AlC system operation Yes Go to the next step.
• Are AlC operation normal? No
Go to the symptom trouble shooting "No.23 AlC DOES
NOT WORK SUFFICIENTLY [WL-C, WE-C]" and
"No.24 AlC ALWAYS ON OR AlC COMPRESSOR
RUNS CONTINUOUSLY [WL-C, WE-C]".
5 Inspect the cooling fan control system operation. Yes Go to the next step.
Does the cooling fan control operate properly? I----::N-=-o---!-=R:-e-p-ai:-r-o-rr-e-p:-Ia-ce---'-:-th-e-m-a-:lf:-u-n-ct:-io-n:-in-g-p-a-:rt-a-c-co-r-:d:-in-g"'-to--1
cooling fan No.2 control system operation inspection
results.
6 Inspect the APP sensor. Yes. Go to the next step.
C, WE-C].)
[WL-C, WE-C].)
8 Visually inspect the CMP sensor and the teeth of Yes Inspect the following PIDs:
the pulse wheel. (See 01-408-10 PCM INSPECTION [WL-C, WE-C].)
Are the CMP sensor and the teeth of the pulse • ECT
wheel normal? • IAT
• MAF
• RPM
9 Remove the thermostat and inspect the Yes Go to the next step.
operation. No Replace thermostat.
(See 01-128-7 THERMOSTAT REMOVAU
(See 01-128-8 THERMOSTAT INSPECTION
[WL-C, WE-C].)
Is the thermostat normal?
01-038-25

10 Inspect the fuel injector relief pressure. Yes Remove and inspect the supply pump and the
Is the fuel injector relief pressure normal? common rail.
No Replace the fuel injector.
(See 01-148-15 FUEL INJECTOR REMOVAU
NO.8 ENGINE RUNS ROUGH/ROLLING IDLE [WL-C, WE-C]

dcf010300000w37
8 ENGINE RUNS ROUGH/ROLLING IDLE

• Engine the speed fluctuates between specified idle speed and a lower speed and the engine shakes
DESCRIPTION excessively.
• Idle speed is too slow and the engine shakes excessively.
• Air leakage from intake-air system
• Cooling fan system malfunction
• EGR system improper operation
• EGR cooler malfunction
• Fuel leakage
• Fuel filter clogging
• Fuel line restriction
POSSIBLE • ECT sensor or related circuit malfunction
CAUSE • APP sensor or related circuit malfunction
• MAF sensor/lAT sensor No.2 malfunction
• Neutral switch or related circuit malfunction
• Engine compression excessive unbalance for each cylinder
• Unbalanced fuel injection amount for each cylinder
• Fuel injection learning improper
Warning
01-038-26
Inspect the following: Yes Go to the next step.
• Fuel quality (e.g.: including water No Service if necessary
• Loose bands on intake-air system
• Cracks on intake-air system parts
• Vacuum leakage
• Cooling fan system operation
2 Is the engine overheating? Yes Go to symptom troubleshooting "NO.1? COOLING
C)."
201,203,205
204,206)
vehicles with the AlC system. If the Go to the symptom troubleshooting "NO.24 AlC
following test cannot be performed due to ALWAYS ON OR AlC COMPRESSOR RUNS
engine stalling, go to the next step. CONTINUOUSLY [WL-C, WE-Cr.
• Go to the next step for vehicles without an Other symptoms:
AlC system. Inspect the following:
Connect the pressure gauge to the AlC line. • Cooling fan operation
Turn the blower and the AlC switches on.
5 Depress the accelerator pedal slightly. Yes Inspect the idle speed.
Crank the engine. (See 01-108-21 ENGINE TUNE-UP [WL-C, WE-C).)
Does the engine start now? No Go to the next step.
C, WE-C).)
? Inspect for fuel leakage from the fuel pipe. Yes Repair or replace if necessary.
Is any fuel leakage found on the fuel pipe? No Go to the next step.
[WL-C, WE-C).)
01-038-27

the pulse wheel. (See 01-40B-10 PCM INSPECTION [WL-C, WE-C].)
• MAF
• RPM
(See 01-40B-33 FUEL PRESSURE SENSOR No Replace common rail.
[WL-C, WE-C].) -
[WL-C, WE-C].) (See 01-14B-15 FUEL INJECTOR REMOVAU
Is the fuel injector normal? INSTALLATION [WL-C, WE-C).)
14 Inspect the EGR cooler for the following: Yes Remove and inspect the supply pump and common
• Coolant passage clogging/restriction rail.
• Exhaust gas clogging/restriction No Service if necessary.
Is EGR cooler normal?
NO.9 FAST IDLE/RUNS ON [WL-C, WE-C]

dcf010300000w38
9 RUNS IDLE/RUNS ON
DESCRIPTION • Engine speed continues at fast idle after warm-up.

• Engine runs after the engine switch is turned off.
• Vacuum leakage
• Improper engine oil level
POSSIBLE Warning
CAUSE The following troubleshooting flow chart contains the fuel system diagnosis and repair
01-038-28
Verify the following: Yes Go to the next step.
- Proper dipstick No Service if necessary.
- Engine oil level Repeat Step 1.
Are all item normal?
2 Connect the current diagnostic tool to the DLC- Yes Go to the next step.
2. No ECT PID is higher than 112 °C{233 OF}:
Access the ECT PID. Go to the symptom troubleshooting "NO.1? COOLING
Start and warm-up the engine to normal SYSTEM CONCERNS-OVERHEATING [WL-C, WE-
operating temperature. C]".
Is the ECT PID reading between 82-112 °C ECT PID is less than 82 °C{180 OF}:
{180-233 OF}? Go to the symptom troubleshooting "NO.18 COOLING
3 Perform the self-test function using the current Yes DTC is displayed:
diagnostic tool. Go to the appropriate DTC test.
201,203,205
204,206)
(See 01-14B-16 FUEL INJECTOR INSPECTION No Replace the fuel injector.
[WL-C, WE-C).) (See 01-14B-15 FUEL INJECTOR REMOVAU
Is the fuel injector normal? INSTALLATION [WL-C, WE-C].)
5 Inspect the APP sensor. Yes Inspect the vacuum leakage.
(See 01-40B-28 ACCELERATOR PEDAL No Replace the accelerator component.
C, WE-C].)
01-038-29
NO.10 LOW IDLE/STALLS DURING DECELERATION [WL-C, WE-C]
dcf010300000w39
10 LOW IDLE/STALLS DURING DECELERATION

DESCRIPTION • Engine stops unexpectedly at the beginning of deceleration or recovery from deceleration.
• Fuel leakage
• Fuel line restriction or clogging
• Fuel filter restriction or clogging
POSSIBLE • Low engine compression
CAUSE • Improper valve timing
Warning
1 Does the engine idle roughly? Yes Go to the symptom troubleshooting "NO.8 ENGINE
RUNS ROUGH/ROLLING IDLE [WL-C, WE-Cr.
• Fuel line/fuel filter clogging or restriction No Service if necessary.
• Intake-air system restriction or clogging Repeat Step 2.
• Fuel quality (e.g.: include water
contamination, winter/summer blend)
201,203,205
204,206)
4 Inspect idle speed. Yes Go to the next step.
(See 01-10B-21 ENGINE TUNE-UP [WL-C, WE- No Repair or replace the malfunctioning part according to
C].) the idle speed inspection results.
01-038-30

C, WE-C].)
[WL-C, WE-C).)
• MAF
• RPM
10 Inspect fuel injector: Yes Go to the next step.
[WL-C, WE-C].) (See 01-148-15 FUEL INJECTOR REMOVAU
Is fuel injector normal? INSTALLATION [WL-C, WE-C).)
vehicles with an AlC system. If the Go to the symptom troubleshooting "NO.24 AlC
• Go to the next step for vehicles without an Other symptoms:
AlC system. Inspect the following:
Connect the pressure gauge to AlC line. • Cooling fan operation
Turn the blower and AlC switches on.
13 Inspect the glow system operation. Yes Remove and inspect the supply pump and common
(See 01-138-9 GLOW PLUG RELAY 1----:-:--_t-:r::-
ai_1.- : - - - ; : - - - - - - - - - - - - - - - 1
INSPECTION [WL-C, WE-C].) No Service if necessary.
Is glow system operation normal?
01-038-31
NO.11 ENGINE STALLS/QUITS, ENGINE RUNS ROUGH, MISSES, BUCK/JERK, HESITATION/STUMBLE,
SURGES [WL-C, WE-C]
dcf010300000w40
ENGINE STALLS/QUITS, ENGINE RUNS ROUGH, MISSES, BUCK/JERK, HESITATION/STUMBLE,

11
SURGES
• Engine stops unexpectedly at beginning of acceleration or during cruise.
• Engine stops unexpectedly while cruising.
• Engine speed fluctuates during acceleration or cruising.
DESCRIPTION • Engine misses during acceleration or cruising.
• Vehicle bucks/jerks during acceleration, during or deceleration.
• Momentary pause at beginning of acceleration or during acceleration.
• Momentary minor irregularity in engine output.
• Turbocharger malfunction
• Cooling fan No.1 or cooling fan No.2 seat are improper
• Fuel line restriction or clogging
• Fuel filter restriction or clogging
• Fuel inlet-filter restriction or clogging
• Boost sensor or related circuit malfunction
POSSIBLE • MAF sensor/IAT sensor No.2 or related circuit malfunction
CAUSE • IAT sensor No.1 or related circuit malfunction
• VSS or related circuit malfunction
• Exhaust system and/or oxidation catalytic converter restriction
• Clutch slippage
Warning
1 Is the idle speed stable? Yes Go to the next step.
No Go to symptom troubleshooting "NO.8 ENGINE RUNS
ROUGH/ROLLING IDLE [WL-C, WE-C]".
2 Is the engine overheating? Yes Go to symptom troubleshooting "NO.1? COOLING
C]".
I -
01-038-32

(Engine-off) . Communication error message is displayed:
201,203,205
204,206)
• Fuel quality (e.g.: including water No Service if necessary.
• Fuel line/fuel filter clogging and/or restriction
• Fuel inlet-filter clogging and/or restriction
• Exhaust system and/or oxidation catalytic
converter restriction
• Cooling fan seat
5 Does the engine run normal after warm-up? Yes Inspect the glow system operation.
(See 01-13B-9 GLOW PLUG RELAY INSPECTION
[WL-C, WE-C].)
vehicles with an AlC system. If the Go to the symptom troubleshooting "NO.24 AlC
engine stalling, go to the next step. CONTINUITY [WL-C, WE-C]".
• Go to the next step for the vehicles an Other symptoms:
without AlC system. Inspect the following:
Connect the pressure gauge to AlC line. • Cooling fan operation
7 Inspect the hose bands between the following Yes Retighten the hose bands.
parts: If the concern is resolved, the inspection is complete.
• Turbocharger compressor housing and air If the concern still exists, go to the next step.
cleaner No Go to the next step.
• Turbocharger compressor housing and
charge air cooler
Are the hose bands loose?
8 Inspect for improper operation, kinks, clogging or Yes Turbocharger is normal.
disconnection on the guide blade actuator. Go to the next step.
Is the guide blade actuator normal? No Repair or replace if necessary.
If concern is resolved, the inspection is complete.
If concern still exists, the turbocharger is normal.
9 Perform the EGR system inspection. Yes Go to the next step.
Is the EGR system normal? No Repair or replace the malfunctioning part according to
The EGR system operation results.
(See 01-10B-21 ENGINE TUNE-UP [WL-C, WE- No Repair or replace the malfunctioning part according to
C].) idle speed inspection results.
(See 01-40B-28 ACCELERATOR PEDAL No Replace the accelerator pedal component.
C, WE-C].)
01-038-33

12 Inspect the adjustment of the neutral switch. Yes Go to the next step.
(See 01-408-43 NEUTRAL SWITCH No Adjust the neutral switch correctly.
Is the neutral switch adjusted correctly?
[WL-C, WE-C].)
• MAF
• RPM
[WL-C, WE-C).)
17 Inspect fuel injector. Yes Go to the next step.
[WL-C, WE-C].) (See 01-148-15 FUEL INJECTOR REMOVAU
18 Inspect the timing belt for the following: Yes Inspect the following:
• Chipping of gear teeth • Clutch slippage
• Low tension • CKP sensor
• 8reakage damage or cracks • VSS
Is the timing belt normal? If normal, remove and inspect the supply pump and
common rail.
No If the timing is incorrect, adjust the valve timing.
If the timing belt is not normal, replace the timing belt.
01-038-34
NO.12 LACK/LOSS OF POWER-ACCELERATION/CRUISE [WL-C, WE-C]
defO 10300000w41
12 LACK/LOSS OF POWER-ACCELERATION CRUISE

DESCRIPTION • Performance is poor under load (e.g., power down when climbing hills).
• Improper operation of AlC cut-off control
• Variable boost control (VBC) system malfunction
• Vacuum leakage
• Clutch slippage
• Fuel line or clogging or restriction
• Fuel inlet-filter clogging or restriction
• IAT sensor No.1 or related circuit malfunction
POSSIBLE
CAUSE
•. Low engine compression
• Cooling fan seat is improper
• Charge air cooler malfunction
• Brake system dragging
• Intake shutter valve malfunction
• Guide blade valve malfunction
Warning
1 Is the idle speed stable? Yes Go to the next step.
No Go to the symptom troubleshooting "NO.8 ENGINE
RUNS ROUGH/ROLLING IDLE [WL-C, WE-C]".
2 Is the engine overheating? Yes Go to the symptom troubleshooting "NO.1? COOLING
Cl"·
01-038-35

Turn the engine switch to the ON position (See 01-028-11 DTC TA8LE [WL-C, WE-C).)
I:" . "
201,203,205
204,206)
• Charge air cooler condition (restriction or
damaged)
• Vacuum leakage
• Cooling fan seat
5 Inspect the intake shutter valve operation. Yes Repair or replace if necessary.
(See 01-038-62 ENGINE CONTROL SYSTEM No Go to the next step.
OPERATION INSPECTION [WL-C, WE-C].)
6 Inspect the guide blade valve operation. Yes Repair or replace if necessary.
7 Inspect the AlC cut-off operation. Yes Go to the next step.
Does the AlC cut-off work properly? No Repair or replace the malfunctioning part according to
AlC cut-off system inspection results.
charge air cooler
9 Inspect for improper operation, kinks, clogging or Yes Go to the next step.
disconnection on guide blade actuator. No Repair or replace if necessary.
(See 01-038-62 ENGINE CONTROL SYSTEM If the concern is resolved, the inspection is complete.
OPERATION INSPECTION [WL-C, WE-C].) If the concern still exists, the turbocharger is normal.
Is actuator normal? Go to the next step.
10 Remove parts necessary to inspect the Yes Replace the turbocharger.
turbocharger. No Go to the next step.
Do not remove the turbocharger.
Inspect if the turbocharger compressor wheel is
bent, damaged, or interfering with the housing
on vehicle.
11 Inspect if the turbocharger compressor wheel Yes Replace the turbocharger.
locknut is loose or has fallen down inside the No Go to the next step.
turbocharger.
12 Inspect if turbocharger compressor wheel by Yes Go to the next step.
hand. No Replace the turbocharger.
Does wheel turn easily and smoothly?
01-038-36

13 Inspect if turbocharger turbine wheel is Yes Replace the turbocharger.
damaged, cracked or interfering with the housing No Go to the next step.
on the vehicle.
Note
• Inspect all fins on each turbine wheel.

14 Is any engine oil found inside the turbocharger Yes Excessive amount of oil is found:
turbine housing? Replace the turbocharger.
Small amount of oil is found:
Wipe oil off of the vehicle, then go to the next step.
15 Is any engine oil found inside the turbocharger Yes Wipe oil off of vehicle and install all removed parts in
compressor housing? Step 11. Then, go to the next step.
No Turbocharger is normal.
Install all the parts removed in Step11.
Then, go to the next step.
17 Inspect idle speed. Yes Go to the next step.
(See 01-108-21 ENGINE TUNE-UP [WL-C, WE- No Repair or replace the malfunctioning part according to
C].) the idle speed inspection results.
C, WE-C].)
19 Visually inspect the CKP sensor and the teeth of Yes Go to the next step.
the pulse wheel. No Replace the malfunctioning parts.
Are the CKP sensor and the teeth of the pulse
wheel normal?
[WL-C, WE-C].)
• MAF
• MAP
• RPM
[WL-C, WE-C].)
01-038-37

Is fuel injector normal? INSTALLATION [WL-C, WE-C].)
• Breakage damage or cracks • Boost sensor and related circuit
Is the timing belt normal? • Brake system for dragging
If normal, remove and inspect the supply pump and
common rail.
No If the valve timing is incorrect, adjust the valve timing.
NO.13 KNOCKING/PINGING [WL-C, WE-C]

dcf010300000w42
13 KNOCKING/PINGING
DESCRIPTION • Excessive shrilly knocking sound from engine.
• Intake shutter valve stuck close
• Low coolant temperature
• Boost sensor or related malfunction
POSSIBLE • Fuel pressure sensor or related circuit malfunction
CAUSE • Accelerator pedal position (APP) sensor or related circuit malfunction
• Fuel return line clogging or restriction
Warning
01-038-38
Does the engine run cold? Yes Go to symptom troubleshooting "NO.18 COOLING
SYSTEM CONCERNS-RUNS COLD [WL-C, WE-Cr.
• Fuel return line clogging and/or restriction
converter restriction or clogging
damaged)
3 Connect the current diagnostic tool to the DLC- Yes Go to the next step.
2. No Inspect the ECT PID.
Access ECT PID.
Verify that the ECT PID is above 80°C {176
OF}?
201,203,205
204,206)
7 Inspect the hose bands between the following Yes Retighten hose bands.
charge air cooler
disconnection on the guide blade actuator. t----:N-=-o--f-:R=-e-p-a-=-ir-o-r-re-p-:I-ac-e-':-:-if-n-ec-e-s-s-a-ry-.- - - - - - - - - 1
OPERATION INSPECTION [WL-C, WE-C).) If the concern still exists, the turbocharger is normal.
Is the actuator normal? Go to the next step.
9 Remove parts necessary to inspect the Yes Replace turbocharger.
bent, damaged, or interfering with housing on
vehicle.
(See 01-138-5 TUR80CHARGER
10 Inspect if turbocharger compressor wheel Yes Replace turbocharger.
turbocharger.
01-038-39

11 Inspect the turbocharger compressor wheel by Yes Go to the next step.
Does the wheel turn easily and smoothly?
12 Inspect if the turbocharger turbine wheel is Yes Replace the turbocharger.
damaged, cracked or interfering with housing on No Go to the next step.
vehicle.
Note

Wipe oil off of vehicle, then go to the next step.
14 Is any engine oil found inside the turbocharger Yes Wipe oil off of the vehicle and install all removed parts
compressor housing? in Step 10. Then, go to the next step.
Install all parts removed in Step10.
16 Inspect the glow system operation. Yes Go to the next step.
(See 01-138-9 GLOW PLUG RELAY No Repair or replace the malfunctioning part according to
INSPECTION [WL-C, WE-C].) glow system operation results.
Is the glow system operation normal?
[WL-C, WE-C].)
18 Visually inspect the CMP sensor and the teeth of Yes Inspect the following PI Os:
• MAF
• MAP
• RPM
20 Inspect the supply pump. Yes Inspect the following:
(See 01-148-11 SUPPLY PUMP REMOVAU • 800st sensor
INSTALLATION [WL-C, WE-C].) • MAF sensor/lAT sensor No.2
Is the supply pump normal? • IAT sensor No.1
• Fuel pressure sensor
• APP sensor
No Replace the supply pump.
(See 01-148-11 SUPPLY PUMP REMOVAU
01-038-40

• If normal, return to the diagnostic index to service any additional symptoms ..
(See 01-03B-6 SYMPTOM DIAGNOSTIC INDEX [WL-C, WE-C).)
NO.14 POOR FUEL ECONOMY [WL-C, WE-C]
14 POOR FUEL ECONOMY

DESCRIPTION • Fuel economy is unsatisfactory.
• Intake -air system clogging or restriction
• Engine cooling system malfunction
• Improper coolant level
• Exhaust system and/or oxidation catalytic converter clogging
POSSIBLE • Incorrect fuel injection timing
CAUSE • Fuel injector malfunction
• Fuelleakage
• Fuel inlet-filter clogging or restriction
• Brake dragging
• Vacuum leakage
• Clutch slippage
• Coolant heater system malfunction
Warning
01-038-41
• Fuel line leakage
damaged)
• Vacuum leakage
2 Is the brake system functioning properly? Yes Go to the next step.
No Inspect for cause.
Turn the engine switch to the ON position (See 01-02B-11 DTC TABLE [WL-C, WE-C).)
201,203,205
204,206)
the vehicles with an AlC system. If the Go to the symptom troubleshooting "NO.24 AlC
• Go to the next step for vehicles without n Other symptoms:
AlC system Inspect the following:
Connect the pressure gauge to the AlC line.
• Cooling fan operation
Is the pressure within the specifications?
5 Access the ECT PID. Yes Go to the next step.
Drive the vehicle while monitoring the PID. No Inspect for coolant leakage, cooling fan operation or
Is the PID within the specification? thermostat operation.
(See 01-10B-21 ENGINE TUNE-UP [WL-C, WE- No Go to symptom troubleshooting "NO.7 SLOW
C).) RETURN TO IDLE [WL-C, WE-Cr.
Is the idle speed normal?
(See 01-40B-28 ACCELERATOR PEDAL No Replace the accelerator pedal component.
C, WE-C].)
[WL-C, WE-C).)
01-038-42

(See01-14B-16 FUEL INJECTOR INSPECTION No Repair or replace if necessary.
11 Perform the turbocharger inspection. Yes Go to the next step.
(See 01-13B-5 TURBOCHARGER No Replace the turbocharger.
Is the turbocharger normal?
(See 01-03B-62 ENGINE CONTROL SYSTEM No Go to the next step.
OPERATION INSPECTION [WL-C, WE-C).)
Is the there any malfunction?
(See 01-40B-39 CRANKSHAFT POSITION No Replace the CKP sensor.
[WL-C, WE-C].)
• MAF
• MAP
• RPM
• VSS
• Breakage damage or cracks • Boost sensor and related circuit
Is the timing belt normal? • Brake system for dragging
• Coolant heater system
• Glow system
If normal, remove and inspect supply pump.
No If the timing is incorrect, adjust the valve timing.
01-038-43
NO.15 EMISSION COMPLIANCE [WL-C, WE-C]
dcf010300000w44
15 EMISSION COMPLIANCE
DESCRIPTION • Fails emissions test.
• Vacuum leakage
• Intake shutter valve stuck close
• Guide blade valve malfunction
• EGR cooler malfunction
• Low coolant temperature
• MAF sensor/IAT sensor No.2 related circuit malfunction
• APP sensor or related circuit malfunction
POSSIBLE • Fuel line clogging or restriction
CAUSE • Supply pump malfunction
• Base engine malfunction
• Oxidation catalytic converter malfunction
Warning
01-038-44
Is the engine overheating? Yes Go to the symptom troubleshooting "NO.17 COOLING
C]".
2 Does the engine run cold? Yes Go to the symptom troubleshooting "NO.18 COOLING
Perform the self-test function using the current (See 01-028-11 DTC TA8LE [WL-C, WE-C).)
diagnostic tool. Communication error message is displayed:
Turn the engine switch to the ON position Inspect the following:
(Engine off). • Open circuit between main relay and PCM terminal
Retrieve any DTCs. 201,203,205
Are any DTCs displayed? • Open circuit main relay and PCM terminal 219
204,206)
• Fuel return line clogging and/or restriction
damaged)
• Vacuum leakage
C, WE-C].)
6 Inspect the adjustment of neutral switch. Yes Go to the next step.
(See 01-408-43 NEUTRAL SWITCH No Adjust the neutral switch correctly.
Is the neutral switch adjusted correctly?
OPERATION INSPECTION [WL-C, WE-C).)
charge air cooler
disconnection on guide blade actuator. No Repair or replace if necessary.
OPERATION INSPECTION [WL-C, WE-C).) If the concern still exists, turbocharger is normal.
01-038-45

vehicle.
(See 01-138-5 TUR80CHARGER
turbocharger.
14 Inspect if the turbocharger turbine wheel is Yes Replace turbocharger.
on vehicle.
Note

compressor hosing? in Step 10. Then, go to the next step.
Install all parts removed in Step10.
18 Inspect the EGR cooler for the following: Yes Go to the next step.
• Coolant passage clogging/restriction No Service if necessary.
• Exhaust gas clogging/restriction
Is the EGR cooler normal?
19 Inspect the glow system operation. Yes Go to the next step.
(See 01-138-9 GLOW PLUG RELAY No Repair or replace the malfunctioning part according to
INSPECTION [WL-C, WE-C].) glow system operation results.
Is the glow system operation normal?
[WL-C, WE-C).)
• MAF
• MAP
• RPM
• VSS
01-038-46

(See 01-40B-33 FUEL PRESSURE SENSOR No Replace the common rail.
[WL-C, WE-C).) • Damaged valve seat
• Chipping of gear teeth • ECT sensor
• Low tension • Boost sensor
• Breakage damage or cracks • MAF sensor/lAT sensor No.2
Is the timing belt normal? • Oxidation catalytic converter
If normal, remove and inspect the supply pump and
common rail.
No If the timing is incorrect, adjust the valve the timing.
NO.16 HIGH OIL CONSUMPTION/LEAKAGE [WL-C, WE-C]

dcf010300000w45
16 HIGH OIL CONSUMPTION/LEAKAGE

DESCRIPTION • Oil consumption is excessive.
• Improper engine oil level
• Improper dipstick
POSSIBLE • Improper engine oil viscosity
CAUSE • Engine internal parts malfunction
• Oil leakage
1 Verify the following: Yes Go to the next step.
• Proper dipstick No Service if necessary.
• Proper engine viscosity Repeat Step 1.
• Engine oil level
2 Remove if necessary to inspect the Yes Replace the turbocharger.
Note
• Do not remove the turbocharger.

vehicle.
locknut is loose or has fallen down inside No Go to the next step.
turbocharger.
01-038-47

4 Turn the turbocharger compressor wheel by Yes Go to the next step.
on the vehicle.
Note
•Inspect all fins on each turbine wheel.

7 Is any engine oil found inside the turbocharger Yes Wipe oil off of vehicle, then go to the next step.
compressor housing? No Go to the next step.
8 Is any engine oil found around oil pipes attached Yes If oil leaks from a damaged pipe, replace the oil pipe.
on turbocharger center housing? Then, go to the next step.
9 Is any engine oil found inside air intake pipes or Yes Wipe engine oil off.
hoses? No Turbocharger is normal.
Install all parts removed in Step 2.
Then go to the next step.
10 Is the engine compression correct? Yes Inspect for oil leakage from outside of engine.
[WL-C, WE-C].)
NO.17 COOLING SYSTEM CONCERNS-OVERHEATING [WL-C, WE-C]

dcf010300000w46
17 COOLING SYSTEM CONCERNS-OVERHEATING

DESCRIPTION • Engine runs at higher than normal temperature/overheats.
• Cooling fan malfunction
• Low drive belt tension
• Drive belt damage
• Improper coolant level
• Thermostat malfunction
POSSI8LE • Radiator clogging
CAUSE • Improper water/anti-freeze mixture
• Improper or damaged radiator cap
• Radiator hose damage
• Coolant leakage (engine internal, turbocharger, external)
• Ale system malfunction
01-038-48
... nn~i'i,. Procedure
Inspect the following:

• Engine coolant level Service if necessary.
• Coolant leakage (around heater unit in Repeat Step 1.
passenger compartment, coolant hoses and/
or radiator, and around coolant heater unit.)
• Water and anti-freeze mixture
• Radiator condition
• Collapsed or restricted radiator hoses
• Radiator pressure cap
• Drive belt tension
• Drive belt
• Fan rotational direction
201,203,205
204,206)
3 Note
• The following test should be performed on Go to the symptom troubleshooting "NO.24 AlC
the vehicles with an AlC system. Go to the ALWAYS ON OR AlC COMPRESSOR RUNS
next step for vehicles without an AlC CONTINUOUSLY [WL-C, WE-Cr.
system
Start the engine and run it at idle speed.

Turn the AlC switch off.
Does the AlC compressor disengage?
4 Is the drive belt normal?
5 Is there any leakage around heater unit in

passenger compartment?
6 Is there any leakage at coolant hoses and/or
radiator?
7 Perform the EGR system inspection.
Is the EGR system normal?
8 Perform the coolant heater system inspection.

(See 01-12B-8 THERMOSTAT INSPECTION Repair or replace the malfunctioning part according to
[WL-C, WE-C].) the coolant heater system operation results. '
Is the coolant heater system normal?
9 Cool down engine. Yes Thermostat is normal.
Remove the thermostat and inspect the Inspect the cylinder block for leakage or blockage.
operation. No Replace thermostat.
(See 01-03B-6 SYMPTOM DIAGNOSTIC INDEX [WL-C, WE-C].) ,.
01-038-49
NO.18 COOLING SYSTEM CONCERNS-RUNS COLD [WL-C, WE-C]
dcf01030000OW47
18 COOLING SYSTEM CONCERNS-RUNS COLD

DESCRIPTION • Engine takes excessive period of time to reach normal operating temperature.
• Thermostat malfunction
POSSIBLE
CAUSE • Cooling fan system malfunction
1 Is the customer complaint "Lack of passenger Yes Inspect the AlC heater system.
compartment heat"? No Go to the next step.
2 Does the engine speed continue at fast idle? Yes Go to the symptom troubleshooting "NO.7 SLOW
RETURN TO IDLE [WL-C, WE-Cr.
3 Remove the thermostat and inspect the Yes Go to the next step.
operation. No Replace the thermostat.
(See 01-12B-7 THERMOSTAT REMOVAU
(See 01-12B-8 THERMOSTAT INSPECTION
[WL-C, WE-C].)
NO.19 EXCESSIVE BLACK SMOKE [WL-C, WE-C]

dcf010300000w48
19 EXCESSIVE BLACK SMOKE

DESCRIPTION • Excessive black smoke is observed in exhaust gas.
• Intake-air system clogging or restriction
• Air leakage from Intake-air system
• Base engine malfunction
POSSIBLE • EGR system malfunction
CAUSE • Variable boost control (VBC) system malfunction
• Vacuum leakage
• Intake shutter valve malfunction
• Exhaust system and/or oxidation catalytic converter restriction or clogging
• Mass airflow sensor malfunction
Warning
01-038-50
Inspect the following:

• Intake-air system clogging or restriction Service if necessary.
• Exhaust system and/or oxidation catalytic Repeat Step 1.
converter restriction or clogging
damaged)
diagnostic tool. Go to the appropriate OTC test.
Turn the engine switch to the ON position (See 01-02B-11 OTC TABLE [WL-C, WE-C].)
Retrieve any OTCs. Inspect the following:
Are any OTCs displayed? • Open circuit between main relay and PCM terminal
201,203,205
204,206)
No No displayed:
Go to next step.
3 Ooes any other symptom exist?
4 Inspect the air cleaner element for clogging.

Is the air cleaner element normal?
5 Inspect intake shutter valve operation.
(See 01-03B-62 ENGINE CONTROL SYSTEM
6 Inspect the guide blade valve operation.
(See 01-03B-62 ENGINE CONTROL SYSTEM
7 Inspect the CKP sensor.
(CKP) SENSOR INSPECTION [WL-C, WE-C].)
[WL-C, WE-C].)
8 Visually inspect the CMP sensor and the teeth of Yes Inspect the following PIOs:
Are the CMP sensor and the teeth of the pulse • IAT
wheel normal? • MAP
• RPM
• MAF
If the PIO value is not as specified, repair or replace
If the PIO value is normal, go to the next step.
9 Perform the EGR system inspection.

Is the EGR system normal? Repair or replace the malfunctioning part according to
10 Inspect the hose bands between following parts: Yes Retighten the hose bands.
• Turbocharger compressor housing and air If the concern is resolved, the inspection is complete.
cleaner If the concern still exists, go to the next
• Turbocharger compressor housing and No Go to the next step.
charge air cooler
11 Inspect for improper operation, kinks, clogging or
disconnection on guide blade actuator. Repair or replace if necessary.
(See 01-03B-62 ENGINE CONTROL SYSTEM If the concern is resolved, the inspection is complete.
OPERATION INSPECTION [WL-C, WE-C].) If the concern still exists, turbocharger is normal.
01-038-51

vehicle.
turbocharger.
Does wheel turn easily and smoothly?
on vehicle.
Note

compressor housing? in Step 15. Then, go to the next step.
Install all parts removed is Step 15. Then, go to the
next step.
[WL-C, WE-C].)
18 Inspect the fuel injector. Yes Inspect the following:
(See 01-148-16 FUEL INJECTOR INSPECTION • 800st sensor
[WL-C, WE-C].) • Fuel pressure limiter (built-in common rail)
Is the fuel injector normal? • Fuel pressure sensor
• Fuel return line restriction or clogging
No Repair or replace if necessary.
(See 01-148-15 FUEL INJECTOR REMOVAU
• Ifthe malfunction remains, inspect the related Service Information and perform repair or diagnosis .
01-038-52
NO.20 FUEL ODOR (IN ENGINE COMPARTMENT) [WL-C, WE-C]
dcf010300000w49
20 FUEL ODOR (IN ENGINE COMPARTMENT)

DESCRIPTION • Fuel smell or visible leakage.
• Fuel leakage
Warning
POSSIBLE
CAUSE
Visually inspect for fuel leakage at the fuel Yes Service if necessary.
injector and fuel line. No Go to the next step.
Is there any fuel leakage?
2 Visually inspect for a damaged or cracked fuel Yes Go to the next step.
filter. No Replace the fuel filter.
Is the fuel filter normal?
(See 01-408-33 FUEL PRESSURE SENSOR No Repair or replace if necessary.
201,203,205
204,206)
Remove and inspect common rail.
01-038-53
NO.21 ENGINE NOISE [WL-C, WE-C]
dcf010300000w50
21 ENGINE NOISE
DESCRIPTION • Engine noise under hood.
• Engine internal damage
• Timing belt displacement
• Loose attaching bolts or worn parts
• Improper drive belt tension
• Incorrect injection timing
POSSIBLE • EGR system or malfunction
CAUSE • IAT sensor No.1 or related circuit malfunction
• Vacuum leakage
• Air in power steering fluid line
• Turbocharger operating noise
• Solenoid valve operating noise
Warning
1 Is there a squeal, click or chirp sound present? Yes Inspect the engine oil level, solenoid valve installation
or the drive belt.
2 Is there a rumble or grind sound present? Yes Inspect the drive belt tension or the power steering
system fluid level.
If normal, perform power steering fluid line air bleed.
3 Is there a rattle sound present? Yes Inspect the location of the rattle for loose parts.
4 Is there a hiss sound present? Yes Inspect for vacuum leakage and intake-air system
leakage.
5 Is there a rap or roar sound present? Yes Inspect the exhaust system for loose parts.
diagnostic tool. Go to the appropriate OTC test.
Turn the engine switch to the ON position (See 01-02B-11 OTC TABLE [WL-C, WE-C].)
Retrieve any OTCs. Inspect the following:
Are any OTCs displayed? • Open circuit between main relay and PCM terminal
201,203,205
204,206)
Go to the appropriate OTC test.
(See 01-02B-11 OTC TABLE [WL-C, WE-C].)
01-038-54

7 Access the ECT PID. Yes Go to the next step.
Inspect the ECT PID while warming up the No Inspect the ECT sensor and the related wiring
engine. harnesses.
Is the PID value correct?
8 Access the IAT PID. Yes Go to the next step.
Inspect the IAT PID while running the engine. No Inspect the IAT sensor No.1 and the related wiring
Is the PID value correct? harnesses.
(CKP) SENSOR INSPECTION [WL-C, WE-C).) Then go to the next step.
[WL-C, WE-C].)
the pulse wheel. (See 01-408-10 PCM INSPECTION [WL-C, WE-C).)
• MAF
• MAP
• RPM
12 Remove parts necessary to inspect the Yes Replace the turbocharger.
Note
• Do not remove the turbocharger.

vehicle.
13 Inspect if the turbocharger compressor wheel Yes Replace turbocharger.
turbocharger.
14 Turn the turbocharger compressor wheel by Yes Go to the next step.
on vehicle.
Note
17 Is any engine oil found inside the turbocharger Yes Wipe oil off of the vehicle, then go to the next step.
compressor housing? No Go to the next step.
18 Is any exhaust gas leakage found around the Yes Remove the turbocharger.
location where the turbocharger is attached to Inspect for cracks on the center housing inlet surface.
the exhaust manifold? If cracks are found, replace the turbocharger.
01-038-55

19 Are any center housing and turbine housing Yes Retighten the loose bolts.
attaching bolts loose? If a bolt is found to be missing, attach appropriate new
bolts.
Install all parts removed in Step 12.
20 Inspect the fuel injector and fuel injector gasket. Yes Inspect the following:
(See 01-14B-16 FUEL INJECTOR INSPECTION • Metal flow
[WL-C, WE-C].) • Bent connecting rod
Is the fuel injector normal? • Damaged valve seat
• Incorrect valve clearance
NO.22 VIBRATION CONCERNS (ENGINE) [WL-C, WE-C]

dcf010300000w51
22 VIBRATION CONCERNS (ENGINE)

DESCRIPTION • Vibration from the under hood or driveline.
• Loose attaching bolts or worn parts
• Cooling fan seat are improper
• Engine or transaxle mounts are improperly installed
• Components malfunction such as worn parts
• MAF sensor/lAT sensor No.2 or related circuit malfunction
• Vacuum leakage
POSSIBLE • Improper tension or damaged drive belts
CAUSE • Improper balance of wheels or tires
• Driveline malfunction
• Suspension malfunction
Warning
1 Inspect the following components for loose Yes Go to the next step.
attaching bolts or worn parts: No Readjust or retighten the engine mount installation
• Cooling fan position.
• Cooling fan seat Service if necessary for other parts.
• Drive belt and pulley
• Engine mounts
• Exhaust system
2 Inspect the vacuum leakage. Yes Go to the next step.
Are the vacuum hoses normal? No Service if necessary.
Repeat Step 2.
01-038-56
Connect the current diagnostic tool to the DLC- displayed:

Retrieve any DTCs. Inspect following:
201,203,205
204,206)
4 Inspect the APP sensor.
C, WE-C].)
• MAF
• RPM
If the PID value is normal, 0 to the next step.
6 Inspect the fuel injector. Inspect the following systems:

(See 01-14B-16 FUEL INJECTOR INSPECTION • Wheels
[WL-C, WE-C].) • Transaxle and mounts
Is the fuel injector normal? • Driveline
• Suspension
7 Verity test results.
NO.23 AlC DOES NOT WORK SUFFICIENTLY [WL-C, WE-C]

dcf010300000w52
23 AlC DOES NOT WORK SUFFICIENTLY

DESCRIPTION • . AlC compressor magnetic clutch does not engage when the AlC switch is turned on.
• Improper refrigerant charge amount
• Open AlC switch magnetic clutch
• Open circuit between AlC relay and AlC magnetic clutch
POSSIBLE • Poor ground of AlC magnetic clutch
CAUSE • Improper AlC magnetic clutch clearance
• Refrigerant pressure switch is stuck open
• AlC relay is stuck open
• Improper AlC cut-off control
• Open circuit between AlC switch and PCM through both refrigerant pressure switch and AlC amplifier
01-038-57
Turn the engine switch to the ON position (See 01-02B-11 DTC TABLE [WL-C, WE-C).)
201,203,205
204,206)
Yes No DTC is displayed:
Go to the appropriate DTC test.
2 Disconnect the AlC compressor connector. Yes Inspect for ground condition of the magnetic clutch on
Start the engine and turn the AlC switch to the the AlC compressor.
ON position. If ground condition is normal, inspect the magnetic
Is there correct voltage at the terminal of the AlC clutch coil for an open circuit.
compressor magnetic clutch connector? No Go to the next step.
Specification
More than 10.5 V
3 Disconnect the refrigerant pressure switch Yes Inspect refrigerant pressure switch operation.
connector. If switch is normal, go to the next step.
Connect jumper wire between terminals of No Inspect the following:
refrigerant pressure switch connector.
Start the engine and turn the AlC switch to the
• AlC switch is stuck open
ON position.
• Open circuit between refrigerant pressure switch
and AlC relay
Is there correct voltage at the terminal of the AlC • Open circuit of blower motor fan switch and
compressor magnetic clutch connector? resistor (if blower motor does not operate)
Specification
More than 10.5 V
• Evaporator temperature sensor and AlC amplifier
4 Inspect the AlC cut-off operation. Yes Go to the next step.
Does the AlC cut-off work properly? No Repair or replace the malfunctioning part according to
the AlC cut-off system inspection results.
5 Remove the jumper wire from the switch Yes Inspect for a stuck open AlC relay.
connector. Replace if necessary.
Reconnect the connector to the refrigerant No Inspect following and repair or replace if necessary:
pressure switch.
Start the engine and turn the AlC switch on.
Does the AlC operate?
• Seized AlC compressor
(See 01-03B-6SYMPTOM DIAGNOSTIC INDEX [WL-C, WE-C].)
01-038-58
NO.24 AlC ALWAYS ON OR AIC COMPRESSOR RUNS CONTINUOUSLY [WL-C, WE-C]
dcf010300000w53
24 AlC ALWAYS ON OR AlC COMPRESSOR RUNS CONTINUOUSLY

DESCRIPTION • AlC compressor magnetic clutch does not disengage.
• AlC compressor magnetic clutch stuck engagement
• AlC relay is stuck closed
POSSIBLE • Improper AlC compressor magnetic clutch clearance
CAUSE • Short to ground circuit between AlC switch and PCM
• Short to ground circuit between AlC relay and PCM
• AlC relay to magnetic clutch circuit shorts to battery power
Perform the self-test function using the current Yes DTC is displayed:
201,203,205
204,206)
Go to the appropriate DTC test.
2 Start the engine and run it at idle. Yes Inspect the following:
Turn the AlC switch on. • AlC relay is stuck closed
Remove the AlC relay. • Short to ground circuit between AlC relay and
Does the AlC magnetic clutch disengage? PCM terminal 128
If both items are normal, go to the next step.
No Inspect if circuit between AlC relay and magnetic
clutch shorts to battery power circuit.
If circuit is normal, inspect magnetic clutch stuck
engagement or clearance or inspect for a stuck closed
AlC switch.
NO.25 AlC DOES NOT CUT OFF UNDER WIDE OPEN THROTTLE CONDITIONS [WL-C, WE-C]
dcf010300000w54
25 AlC DOES NOT CUT OFF UNDER WIDE OPEN THROTTLE CONDITIONS
DESCRIPTION • AlC compressor magnetic clutch does not disengage under a wide open throttle.
POSSIBLE • Accelerator pedal position (APP) sensor malfunction
CAUSE • Loosely installed APP sensor
1 Does the AlC compressor disengage when the Yes Go to the next step.
AlC switch is turned off? No Go to symptom troubleshooting "NO.24 AlC ALWAYS
ON OR AlC COMPRESSOR RUNS
CONTINUOUSLY".
01-038-59

201,203,205
• Main relay stuck open.
204,206)
Inspect APP sensor.
(See 01-40B-28 ACCELERATOR PEDAL POSITION
(APP) SENSOR INSPECTION [WL-C, WE-C].)
INTERMITTENT CONCERN TROUBLESHOOTING [WL-C, WE-C]

dcf010300000w55
Vibration Method
1. If a malfunction occurs or becomes worse while driving on a rough road, or due to engine vibration, perform the
steps below.
Note
• There are several reasons why the vehicle or engine vibration could cause an electrical malfunction.
Some of the things to check for are:
Connectors not fully seated.
- Wire harnesses not having full play.
- Wires laying across brackets or moving parts.
- Wires routed too close to hot parts.
• An improperly routed, improperly clamped, or loose wiring harness can cause the wiring to become
pinched between parts.
• The connector joints, points of vibration, and places where wire harnesses pass through the fire wall, body
panels, etc. are the major areas to be checked.
Inspection Method for Switch Connectors or Wires

1. Connect the current diagnostic tool to the DLC-2.
2. Turn the engine switch to the ON position (Engine off).
Note
• If the engine starts and runs, perform the following steps at idle.
3. Access the PIDs for the switch you are inspecting.

4. Turn the switch on manually.
5. Shake each connector or wiring harness a bit
vertically and horizontally while monitoring the
PID.
• If the PID value is unstable, check for a poor
,
connection.
1///,./ \~
'// I
,, ,
\
'\..~ \
,
I --'
I I
I "I "
...
I
A6E40802001
01-038-60
Inspection Method for Sensor Connectors or Wires
Note
3. Access the PIDs for the switch you are inspecting.

4. Shake each connector or wiring harness a bit
PID.
• If the PID value is unstable, check for a poor
connection.
Inspection Method for Sensors

Note
3. Access PIDs for the switch you are inspecting.

4. Shake the sensor slightly with your finger.
• If the PID value is unstable or a malfunction occurs, check for a poor connection and/or poorly mounted
sensor.
Inspection Method for Actuators or Relays

Note
3. Prepare the Output State Control for the actuators or relays that you are inspecting.
4. Shake the actuator or relay with your finger for 3 seconds after the Output State Control is activated.
• If a variable click sound is heard, check for a poor connection and/or poorly mounted actuator or relay.
Note
• Shaking the relays too strongly may result in
open relays.
A6E40802003
01-038-61
. SYMPTOM TROUBLESHOOTING [WL-C, WE-C]
Water Sprinkling Method
Caution
• Indirectly change the temperature and humidity by spraying water onto the front of the radiator.
• If a vehicle is subject to water leakage, the leakage may damage the control module. When testing
a vehicle with a water leakage malfunction, special caution must be used.
If a malfunction occurs only during high humidity or rainy/snowy weather, perform the following steps.
1. Connect the current diagnostic tool to the DLC-2 if you are inspecting sensors or switches.
Note
3. Access the PIDs for sensor or switch if you are inspecting sensors or switches.
4. If you are inspecting a switch, turn it on manually.
5. Spray water onto the vehicle or run it through a
car wash.
• If the PID value is unstable or a malfunction
occurs, repair or replace the part if necessary.
A6E40B02004
ENGINE CONTROL SYSTEM OPERATION INSPECTION [WL-C, WE-C]

dcf010300000w56
Guide Blade Actuator Operation Inspection
1. Connect current diagnostic tool to DLC-2.
2. Start the engine and run it at idle.
3. Access the VBCV PID.
4. Verify that the guide blade actuator rod moves when the VBCV PID from 0 to 100 % using simulation function.
• If the rod movement cannot be verified inspect the followings;
Guide blade actuator (See 01-13B-6 GUIDE BLADE ACTUATOR INSPECTION [WL-C, WE-C].)
Vacuum hose conn~ction between the vacuum chamber and the guide blade actuator through the VBC
solenoid valve (See 01-13B-2INTAKE-AIR SYSTEM VACUUM HOSE ROUTING DIAGRAM [WL-C,
WE-C].)
VBC solenoid valve (See 01-13B-6 VARIABLE BOOST CONTROL (VB C) SOLENOID VALVE
Glow Plug Control Operation Inspection

1. Verify that the battery is charged fully.
2. If not, charge the battery.
3. Connect the current diagnostic tool to the DLC.
5. Access and monitor the VPWR and GPL PIDs.
6. Verify that the VPWR PID drops 0.3 V or more while the GPL is turned on from off using the simulation
function.
• If it cannot be verified, inspect the followings;
Glow plug relay
Glow plug
Wiring harness for battery positive post-glow plug relay-glow plug
Wiring harness for PCM terminal 182-glow plug relay-ground
01-038-62
Intake Shutter Valve Operation Inspection
2. Start the engine and run it at idle.
3. Access the IASV and IASV2 PID.
4. Verify that the Intake Shutter Valve actuator rod moves to half open when the IASV PID from OFF to ON and,
full open when the IASV2 PID from OFF to ON using simulation function.
• If the rod movement cannot be verified inspect the followings;
Intake Shutter Valve actuator
Vacuum hose connection between the vacuum chamber and the Intake Shutter Valve actuator through
the ISV solenoid valve
ISV solenoid valve and related harness
Fuel Injector Operation Inspection

2. Start the engine and warm it up to normal operating temperature.
3. Perform the KOER self-test. (See 01-02B-10 KOEO/KOER SELF TEST [WL-C, WE-C].)
4. Verify that DTCs P0200, P0201, P0202, P0203 and/or P0204 are not shown using the KOER self-test.
• If DTC P0200, P0201, P0202, P0203 and/or P0204 are shown, perform the DTC troubleshooting
procedure. (See 01-02B-11 DTC TABLE [WL-C, WE-C].)
5. Verify that the engine speed drops or stalls when each cylinder fuel injector turns to off from on using the
simulation function.
• If it cannot be verified, inspect the following for the suspected cylinder;
Fuel injector (See 01-14B-16 FUEL INJECTOR INSPECTION [WL-C, WE-C].)
- Wiring harness for PCM-fuel injector
01-038-63

MECHANICAL LOCATION CYLINDER HEAD GASKET
INDEX [WL-C, WE-C] .........•..•. 01-10B-2 REPLACEMENT [WL-C, WE-C] .•..•.. 01-10B-9
DRIVE BELT INSPECTION ROCKER ARM REMOVAU
[WL-C, WE-C] •.•..••..••......•.. 01-10B-3 INSTALLATION [WL-C, WE-C] ....... 01-10B-16
DRIVE BELT ADJUSTMENT FRONT OIL SEAL
[WL-C, WE-C] ..•••...•.....•...•. 01-10B-4 REPLACEMENT [WL-C, WE-C] ....... 01-10B-16
VALVE CLEARANCE INSPECTION REAR OIL SEAL
[WL-C, WE-C] •.........••.....•.. 01-10B-5 REPLACEMENT [WL-C, WE-C] .....• 01-10B-18
VALVE CLEARANCE ENGINE REMOVAU
ADJUSTMENT [WL-C, WE-C] .•••... 01-10B-5 INSTALLATION [WL-C, WE-C] ......• 01-10B-19
COMPRESSION INSPECTION ENGINE DISASSEMBLY/
[WL-C, WE-C] •.........••.....•.• 01-10B-6 ASSEMBLY [WL-C, WE-C] ..•..•.... 01-10B-21
TIMING BELT REMOVAU ENGINE TUNE-UP [WL-C, WE-C] ...... 01-10B-21
INSTALLATION [WL-C, WE-C] ..••.•. 01-10B-7
01-108-1
MECHANICAL LOCATION INDEX [WL-C, WE-C]
dcf01100000Ow04
DBG110BWB87
;' ......
'
01-108-2
Engine Timing belt

(See 01-10B-5 VALVE CLEARANCE INSPECTION 3 (See 01-10B-7 TIMING BELT REMOVAU
[WL-C, WE-C].) INSTALLATION [WL-C, WE-C].)
(See 01-10B-5 VALVE CLEARANCE Rocker arm
ADJUSTMENT [WL-C, WE-C].) 4 (See 01-10B-16 ROCKER ARM REMOVAU
1 (See 01-10B-6 COMPRESSION INSPECTION [WL- INSTALLATION [WL-C, WE-C].)
C, WE-C].) Cylinder head gasket
(See 01-10B-19 ENGINE REMOVAU 5 (See 01-10B-9 CYLINDER HEAD GASKET
INSTALLATION [WL-C, WE-C].) REPLACEMENT [WL-C, WE-C].)
(See 01-10B-21 ENGINE DISASSEMBLY/
ASSEMBLY [WL-C, WE-C].) Front oil seal
6 (See 01-10B-16 FRONT OIL SEAL
Drive belt REPLACEMENT [WL-C, WE-C].)
(See 01-10B-3 DRIVE BELT INSPECTION [WL-C,
2 WE-C].) Rear oil seal
(See 01-10B-4 DRIVE BELT ADJUSTMENT [WL-C, 7 (See 01-10B-18 REAR OIL SEAL REPLACEMENT
WE-C].) [WL -C, WE-C].)
DRIVE BELT INSPECTION [WL-C, WE-C]

Drive Belt Deflection Check
1. Check the drive belt deflection when the engine is GENERATOR MEASURING
cold, or at least 30 minutes after the engine has
stopped. Apply pressure 98 N {10 kgf, 22 Ibf}
midway between the specified pulleys.
NC
DBG110AWB301

(mm {in})
Drive Belt New* Used Limit
7.4-9.4 8.7-10.4
{0.30-0.37} {0.35-0.40}
6.1-6.9 7.1-8.0
a 11.3 {0.44} or more
{0.24-D.27} {0.28-0.31}
AlC
10.0-11.0 11.3-12.6
b 17.4 {0.69} or more
{0.40-0.43} {0.45-0.49}
* : A belt that has been on a running engine for less than five minutes.
2. If the deflection is not within the specification, adjust it. (See 01-1 OB-4 DRIVE BELT ADJUSTMENT [WL-C,
WE-C].)
01-108-3
Drive Belt Tension Check
1. Belt tension can be checked in place of belt
deflection. Check the drive belt tension when the
engine is cold, or at least 30 minutes after the
engine has stopped. Using the SST, check the
belt tension between any two pulleys.
DBG110AWB302
Drive Belt Tension
Drive Belt New

. Used Limit
(N {kgf, Ibf})
490-637 431-539
{50. 0-64. 9, 111-143} {44.0-54.9,96.9-121}
455-572 353-431
Ale {46.4-58.3, 103-128} {36.0-43.9, 79.4-96.8}
156 {15.9, 35.1} or less
• : A belt that has been on a running engine for less than five minutes.
2. If the tension is not within the specification, adjust it. (See 01-1 OB-4 DRIVE BELT ADJUSTMENT [WL-C, WE-
C].)
DRIVE BELT ADJUSTMENT [WL-C, WE-C]

dcf01101580Ow04
Generator
1. Loosen the mounting bolt C and locknut A.
2. Adjust the belt deflection or tension by turning adjusting bolt B. (See 01-1 OB-3 DRIVE BELT INSPECTION [WL-
C, WE-C].)
3. Tighten the mounting bolt C and locknut A.
4. Tighten the adjust bolt B. B
A 18.6-25.5
Tightening torque {1.9-2.6,
14-18 }
7.84-9.80 N·m {80-100 kgf·cm, 69.4-86.7
in·lbf}
5. Inspect the belt deflection or tension. (See 01-

10B-3 DRIVE BELT INSPECTION [WL-C, WE- 37.3-51.9
C].) {3.8-5.3,
28-38}
DBG110AWB303
AlC
1. Loosen the locknut A.
2. Adjust the belt deflection or tension by turning adjusting bolt B. (See 01-1 OB-3 DRIVE BELT INSPECTION [WL-
C, WE-C].)
3. Tighten the locknut A.
4. Inspect the belt deflection or tension. (See 01- 37.3-52.0
10B-3 DRIVE BELT INSPECTION [WL-C, WE- {3.8-5.3, A
C].) 28-38 }
DBG110AWB304
01-108-4
VALVE CLEARANCE INSPECTION [WL-C, WE-C]
dcf011012111w03
1. Remove the engine cover.

2. Remove the following parts to turn the crankshaft.
1. Drive belt. (See 01-10B-4 DRIVE BELT ADJUSTMENT [WL-C, WE-C).)·
2. Cooling fan. (See 01-12B-8 COOLING FAN REMOVAUINSTALLATION [WL-C, WE-C].)
3. Water pump pulley.
3. Remove the fuel injector. (See 01-14B-15 FUEL INJECTOR REMOVAUINSTALLATION [WL-C, WE-C].)
5. Turn the crankshaft and align the timing mark so that the piston of the No.1 or No.4 cylinders is at TDC of
compression.
6. Measure valve clearances A with the No.1 B A B A
cylinder at TDC of compression, and those of B
• If it is not within the specification, adjust and EX
recheck the valve clearance. (See 01-1 OB-5
VALVE CLEARANCE ADJUSTMENT [WL-C,
WE-C].)
IN
B B A A
DBG110BEB023
CAMSHAFT
IN: 0.10-0.16 mm {0.0040-0.0062 in}
EX: 0.17-0.23 mm {0.0067-0.0090 in} GAU\
remaining valve clearances. Adjust if necessary. --~~~
8. Install the cylinder head cover. (See 01-1 OB-9
CYLINDER HEAD GASKET REPLACEMENT
[WL-C, WE-C].)
9. Install the fuel injector. (See 01-14B-15 FUEL
ROCKER ARM
INJECTOR REMOVAUINSTALLATION [WL-C,
DBG110BTBRR5
WE-C].)
10. Install the water pump pulley, cooling fan and
drive belt.
11. Adjust the drive belt deflection. (See 01-10B-4 DRIVE BELT ADJUSTMENT [WL-C, WE-C].)
12. Install the engine cover.
VALVE CLEARANCE ADJUSTMENT [WL-C, WE-C]

dcf011012111w04
Caution
• Loosening the locknut and the adjust screw while the cam lobe is not pressing down the rocker
arm will damage the claw of the rocker arm. When loosening the locknut and the adjust screw,
rotate the crankshaft clockwise and be sure that the cam lobe presses down the rocker arm firmly

2. Remove the following parts to turn the crankshaft.
1. Drive belt. (See 01-1 OB-4 DRIVE BELT
ADJUSTMENT [WL-C, WE-C].) CAM LOBE
2. Cooling fan. (See 01-12B-8 COOLI NG FAN
REMOVAL/INSTALLATION [WL-C, WE-C].)
3. Water pump pulley.
3. Remove the fuel injector. (See 01-14B-15 FUEL CLAW
INJECTOR REMOVAL/INSTALLATION [WL-C,
WE-C].) ROCKER ARM
DBG110BTBRR6
5. Turn the crankshaft and align the timing mark so
TDC of compression.
01-108-5
6. Adjust the valve clearances A with the No.1 B A B A
cylinder at TDC of compression, and those of B
DBG110BEB023
CAMSHAFT
IN: 0.10-0.16 mm {0.0040-0.0062 in}
~~~~~
EX: 0.17-0.23 mm {0.0067-0.0090 in}
GAU\_E______
Tightening torque (lock nut)
20-24 N·m {2.1-2.4 kgf·m, 15-17 ft·lbf}

8. Install the cylinder head cover. (See 01-1 OB-9 ROCKER ARM
CYLINDER HEAD GASKET REPLACEMENT
DBG110BTBRR5
[WL-C, WE-C].)
9. Install the fuel injector. (See 01-14B-15 FU EL
INJECTOR REMOVAUINSTALLATION [WL-C, WE-C].)
10. Install the water pump pulley, cooling fan and drive belt.
11. Adjust the drive belt deflection. (See 01-1 OB-4 DRIVE BELT ADJUSTMENT [WL-C, WE-C].)
COMPRESSION INSPECTION [WL-C, WE-C]

dcf01100200Ow03
Warning
• When the engine and the oil are hot, they can badly burn. Turn off the engine and wait until they
are cool.
1. Verify that the battery is fully charged. Recharge it if necessary. (See 01-17-2 BATTERY INSPECTION.)
2. Warm up the engine to the normal operating temperature.
3. Stop the engine and allow it to cool down for about 10 minutes.
Warning
• Fuel line spills and leakage are dangerous. Fuel can ignite and cause serious injuries or death and
damage, Fuel can also irritate skin and eyes. To prevent this, always complete the following "Fuel
Line Safety Procedure". (See 01-14B-3 BEFORE REPAIR PROCEDURE [WL-C, WE-C].)

5. Remove the common rail. (See 01-14B-11 SUPPLY PUMP REMOVAUINSTALLATION [WL-C, WE-CD
6. Remove all the glow plugs. (See 01-13B-8 GLOW PLUG REMOVAUINSTALLATION [WL-C, WE-C].)
01-108-6
7. Install the SSTs into the glow plug hole.
8. Crank the engine and note the maximum gauge
reading.
9. Check each cylinder as above.
Compression (kPa {kgf/cm 2 , psi} [rpm])

Standard: 2,942 {30, 427} [200]
Minimum: 2,648 {27, 384} [200]
10. If the compression in one or more cylinders is low,

pour a small amount of clean engine oil into the
cylinder and recheck the compression.
(1) If the compression increases, the piston, the
piston rings, or cylinder wall may be worn and
overhaul is required.
(2) If the compression stays low, a valve may be stuck or improperly seated and overhaul is required.
(3) If the compression in adjacent cylinders stays low, the cylinder head gasket may be damaged or the
cylinder head distorted and overhaul is required.
11. Remove the SST.
12. Install the glow plug. (See 01-138-8 GLOW PLUG REMOVAL/INSTALLATION [WL-C, WE-C].)
13. Install the common rail. (See 01-148-11 SUPPLY PUMP REMOVAL/INSTALLATION [WL-C, WE-CD
TIMING BELT REMOVAUINSTALLATION [WL-C, WE-C]

dcf011012040w02

2. Disconnect the negative battery cable.
3. Remove in the order indicated in the table.
4. Install in the reverse order of removal.
37-52 {3.7-5.3,
27-38}
~
~~
70-95 in·lbf}

DBG110BWB99
1 Timing belt cover 3 Idler

(See 01-10B-9 Timing Belt Cover Installation 4 Timing belt
Note.) (See 01-10B-8 Timing Belt Removal Note.)
2 Tensioner (See 01-10B-9 Timing Belt Installation Note.)
(See 01-10B-8 Tensioner Removal Note.)
(See 01-10B-9 Timing Belt Installation Note.)
01-108-7
Tensioner Removal Note
1. Turn the crankshaft clockwise and align the timing INTAKE
marks as shown. EXHAUST
CAMSHAFT CAMSHAFT
PULLEY PULLEY
DBG110BWB98
2. Turn the auto tensioner counterclockwise using

an Allen wrench. (Rotate the auto tensioner with a c
force of 39 N·m {4.0 kgf·m, 28.8 ft.lbf} or less.)
3. Insert a fixing pin of approx. Smm {O.24 in}
diameter into hole A to secure the auto tensioner.
t
4. Remove the bolts in the order of Band C, then
remove the auto tensioner.
Note 39 N·m {4.0 kgf·m, 28.8 ft·lbf}

• If the rod projects suddenly while removing MAX.
the auto tensioner, the air flows into the
pressure chamber and the rod could move
DBG110BEB033
slightly. If this occurs, bleed the air from the
pressure chamber using the following
procedure.
5. Assemble the auto tensioner to the engine.

6. Turn the auto tensioner with a force of 39 N·m
{4.0 kgf.m, 28.8 ft.lbf} or less using an Allen
wrench, then turn it back slowly. Repeat this
procedure several times.
7. Verify that the rod has resistance when it is in the
most projected position. If there is no resistance,
repeat the above procedure.
REPEAT
39N·m SEVERAL
{4.0 kgf·m, TIMES ALLEN
28.8 ft·lbf} MAX. WRENCH
DBG110BWB999
Timing Belt Removal Note
Caution
• The following will damage the timing belt and shorten its life; forcefully twisting it, turning it inside
out, or getting oil or grease on it. .
• After removing the timing belt, do not move the crankshaft and/or camshaft pulley from this
position because it can cause the valve and piston to contact and damage them.
~~""
reinstallation.
~OTATION
~I ~
30 mm {1.2 in } MIN.
ARROW
NG
DBG110BWB003
01-108-8
Timing Belt Installation Note
1. Align the timing marks as shown. INTAKE
2. Verify that the supply pump attaching bolts and EXHAUST
CAMSHAFT
CAMSHAFT
nuts are tightened to the specified torque. This PULLEY PULLEY
must be done to prevent over-tensioning of the
timing belt after it has been installed.
TIMING MARK
TIMING ~@\-SUPPLY PUMP

MARK ~ PULLEY
3. Install the tensioner and hand-tighten the lock bolt

A and B.
5. Install the idler.
6. Tighten the lock bolt A.
7. Tighten the lock bolt B.
8. Remove the set pin from the tensioner.
camshaft pulley timing marks. If they are not
aligned, remove the timing belt and repeat from
Step 1.
DBG110BWB96
Timing Belt Cover Installation Note

1. Tighten the timing belt cover bolts in the order
shown.
DBG110BEB043
CYLINDER HEAD GASKET REPLACEMENT [WL-C, WE-C]

dcf011010271w02
Warning
• Fuel vapor is hazardous. It can very easily ignite, causing serious injury and damage. Always keep
speaks and flames away from fuel.
• Fuel line spills and leaks are dangerous. Fuel can ignite and cause serious injuries or death and
damage. Fuel can also irritate skin and eyes. To prevent this, always complete the "Fuel Line
Safety Procedures".

3. Drain the engine coolant. (See 01-12B-2 COOLING SYSTEM SERVICE WARNINGS [WL-C, WE-C].)
4. Remove the intake manifold, air intake pipe and breather chamber. (See 01-13B-3 INTAKE-AIR SYSTEM
REMOVAUINSTALLATION [WL-C, WE-C).)
5. Remove the fuel injector. (See 01-14B-15 FUEL INJECTOR REMOVAUINSTALLATION [WL-C, WE-C].)
6. Remove the turbocharger. (See 01-15B-2 EXHAUST SYSTEM REMOVAUINSTALLATION [WL-C, WE-C].)
7. Remove the timing belt. (See 01-10B-7 TIMING BELT REMOVAUINSTALLATION [WL-C, WE-C].)
11. Bleed air in the fuel line. (See 01-14B-4 AFTER REPAIR PROCEDURE [WL-C, WE-C].)
01-108-9
12. Start the engine and
-:1
(1) Inspect for engine oil, engine coolant, and fuel leakage.
(2) Inspect the idle speed.
13. Inspect the compression.
7.8-10.8N·m
{80-110 kgf·cm,
70-95 in.lbf}
i1
4
~'c;o~
~c;o~
29 {3.0, 21}
+ 90°_105°
7.8-10.8 N·m
{80-110 kgf.cm,
70-95 in·lbf}
DBG110BWB95
01-108-10
Cylinder head cover 5 Camshaft

1 (See 01-108-15 Cylinder Head Cover Installation Camshaft cap lower
Note.) 6 (See 01-108-13 Camshaft Cap Lower Installation
Camshaft pulley Note.)
2 (See 01-108-11 Camshaft Pulley Removal. Note.) Cylinder head
(See 01-108-14 Camshaft Pulley Installation Note.) 7 (See 01-108-11 Cylinder Head Removal Note.)
Seal plate (See 01-108-12 Cylinder Head Installation Note.)
3 (See 01-108-14 Seal Plate Installation Note.) Cylinder head gasket
Camshaft cap upper 8 (See 01-108-12 Cylinder Head Gasket Installation
(See 01-108-11 Camshaft Cap Upper Removal Note.)
4 Note.)
(See 01-108-13 Camshaft Cap Upper Installation
Note.)
Camshaft Pulley Removal Note

1. Hold the camshaft by using a wrench on the cast hexagon.
Caution
CAMSHAFT PULLEY
damage them.
DBG110BEBR17
Camshaft Cap Upper Removal Note

steps in the order shown.
Cylinder Head Removal Note

1. Remove bolts A.
steps in the order shown.
DBG110BEBR09
01-108-11
Cylinder Head Gasket Installation Note
1. Measure the piston topping of all the cylinders.
+TOPPING
CYLINDER PISTON
BLOCK
DPE110ZE1R02

piston topping.
Piston topping (mm {in})
identification mark
0.080-0.190 {0.004-0.007} ~
0.135-0.255 {0.006-0.01 O} .-----J IDENTIFICATION MARK

POSITION
0.200-0.310 {0.008-0.012} ++-' DPE110BEBR94

shown. 16.0 mm
{0.63 in}
Thickness ~+-+
02.0-3.0 mm {0.08-0.11 in} 44.0 mm

{1.73 in} ENGINE
FRONT
39.5 mm
>.-l,d-III-+ {1.56 in}
23.5 mm
{0.93 in}
DBG110BWBR9
Cylinder Head Installation Note

1. Measure the length of each bolt. Replace the bolt
if necessary.

Bolt head mark W
~ (( ),),,)))))))))))))
4.007 in}
Bolt head mark N
I. LENGTH
.1
4.480 in}
DBG110AEB097
Bolt head mark I
Standard length: 149-150 mm {5.867-
5.905 in}
.'J
01-108-12
Tighten torque
29 N·m {3.0 kgf·m, 22 ft.lbf}

{3.0 kgf·m, 2.1 ft.lbf}.

PAINT MARK
by turning each 90°-105° in the sequence
shown.
105°.
105°.
9. Apply adhesive to the thread of bolt A.
10. Tighten bolts A.
PAINT MARK
Tightening torque
DBG110AWB311
17.6-19.6 N·m {1.80-1.99 kgf.m, 13.0-14.4
ft.lbf}
Camshaft Cap Lower Installation Note

DBG110BEB105
Camshaft Cap Upper Installation Note

1. Apply adhesive to the front camshaft cap
mounting surfaces as shown.
ADHESIVE
DBG1WBWB86
01-108-13
2. Tighten the camshaft cap bolts gradually in three or four steps in the order shown.
Caution
• Because there is little camshaft thrust
clearance, the camshaft must be held
horizontally while it is installed.
applied to the thrust area, causing burr
cylinder head journal: To avoid this, the

oil seal.
5. Tap the oil seal lightly into the cylinder head using
~
the SST and a hammer.
6. To ensure that the oil seal is installed correctly, 1r!~"'"'iIIiIlII Iii.
cylinder head and the face of the oil seal. I CYLINDER
Camshaft oil seal press-in amount I HEAD 0.5-1.0 mm {0.02-0.03 in}
Ii
0.5-1.0 mm {0.02-0.03 in}
'sMMER
OIL SEAL
DPE110ZE1R41
Seal Plate Installation Note

in the figure.
SEAL PLATE
DBG110BEB041
Camshaft Pulley Installation Note

1. Install the camshaft pulleys, positioning the knock
pins as shown. INTAKE
CAMSHAFT KNOCK PIN
PULLEY
DBG110BWB85
01-108-14
2. Hold the camshaft using a wrench on the cast
hexagon.
CAMSHAFT PULLEY
Caution
damage them.
Cylinder Head Cover Installation Note

shown.
Thickness
02.0-3.0 mm {0.08-0.11 in}
DBG110BWB84

shown.
DBG110BEB005
01-108-15
ROCKER ARM REMOVAL/INSTALLATION [WL-C, WE-C]
dcf011 01201 OW02
Caution
• Removing the camshaft under load can break the camshaft. When removing the camshaft, be sure
to prevent the camshaft from pressing down the rocker arm. (See 01-108-5 VALVE CLEARANCE
ADJUSTMENT [WL-C, WE-C].)

3. Remove the air intake pipe and breather chamber.
4. Remove the timing belt. (See 01-108-7 TIMING 8ELT REMOVAUINSTALLATION [WL-C, WE-C].)
S. Remove the camshaft. (See 01-108-9 CYLINDER HEAD GASKET REPLACEMENT [WL-C, WE-C].)
6. Remove the order indicated in the table.
Rocker arm 20-24 {2.1-2.4, 15-17}
1
11 ~j
~
(See 01-108-16 Rocker Arm Installation Note.)
Pivot
2
(See 01-108-16 Pivot Installation Note.) o /,
4
I
15-19 {1.6-1.9, 11-14} ~
N·m {kgf·m, tt.lbf}

DBG110BWB93
Pivot Installation Note

1. Apply adhesive to the thread of the pivot.
Rocker Arm Installation Note

1. If a new rocker arm is used, set dimension A as
follows.
Dimension A
0.0-4.0 mm {0.0-0.115 in}
DBG110BWB92
FRONT OIL SEAL REPLACEMENT [WL-C, WE-C]

dcf011 01 0602w02
2. Drain the engine coolant. (See 01-128-3 ENGINE COOLANT REPLACEMENT [WL-C, WE-C].)
3. Remove the upper radiator hose.
4. Remove the radiator cowling and cooling fan.
S. Remove in the order indicated in the table.
7. Inspect the engine oil level.
01-108-16
1 Drive belt
mim3~
~9;~y
2 Crankshaft pulley
(See 01-108-17 Crankshaft pulley Removal Note.)
(See 01-108-18 Crankshaft pulley Installation Note.)
1m2 •
.v
3 Front oil seal
(See 01-108-17 Front Oil Seal Removal Note.)
(See 01-108-17 Front Oil Seal Installation Note.) 392-441 /~'I~)
{40-44, ~ ~~&
291l-'~@)l!& 1
N'm {kgf·m, ft·lbf}
Crankshaft pulley Removal Note

Caution
• Turning the crankshaft after the
crankshaft pulley is removed can
dislocate the timing gear.
• Removing the key can cause the key
groove to become misaligned.
Front Oil Seal Removal Note

1. Cut the oil seal lip using a razor knife.
with a rag.
DBG110AWB015
Front Oil Seal Installation Note

hammer. GEAR CASE COVER
gear case cover and the face of the front oil seal.
Pushing distance of the front oil seal 0.0-0.4 mm

{0.0-0.015 in}
0.0-0.4 mm {0.0-0.015 in}
MER
i!ONT OIL SEAL
DBG110BWB006
01-108-17
Crankshaft pulley Installation Note
REAR OIL SEAL REPLACEMENT [WL-C, WE-C]

dcf011011399w02

2. Remove the dual-mass flywheel. (See 05-10-12 CLUTCH UNIT REMOVAUINSTALLATION.)
5. Inspect the engine oil level. (See 01-118-2 ENGINE OIL LEVEL INSPECTION [WL-C, WE-C].)
Rear oil seal
(See 01-108-18 Rear 011 Seal Removal Note.)
(See 01-108-19 Rear Oil Seal Installation Note.)
DBG110AWB316
Rear 011 Seal Removal Note

1. Cut the oil seal lip by using a razor knife.
2. Remove the oil seal by using a screwdriver
protected with a rag.
RAG
DBG110AWB317
01-108-18
Rear Oil Seal Installation Note
hammer. REAR COVER
4. To ensure that the oil seal is installed correctly, I P'-'iII I. t.SI
cover and the face of the rear oil seal.
Pushing distance of the rear oil seal D.O-O.Smm

{D.O-D.Di9 in}
0.0-0.5 mm {0.0-0.019 in}
HAMMER ilROILSEAL
DBG110BWB007
ENGINE REMOVAUINSTALLATION [WL-C, WE-C]
Warning
1. Remove the air intake pipe. (See 01-13B-3 INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [WL-C, WE-C].)
2. Remove the battery. (See 01-17-2 BATTERY REMOVAL/INSTALLATION.)
3. Remove the radiator. (See 01-12B-6 RADIATOR REMOVALIINSTALLATION [WL-C, WE-C].)
4. Remove the front pipe. (See 01-15B-2 EXHAUST SYSTEM REMOVAL/INSTALLATION [WL-C, WE-C].)
5. Remove the transmission. (See 05-11 B-5 TRANSMISSION REMOVAL/INSTALLATION [S15M-D].) (See 05-
11 B-1 0 TRANSMISSION AND TRANSFER REMOVAL/INSTALLATION [S15MX-D].)
6. Remove the PIS oil pump with the oil hoses and pipes still connected. (See 06-14-14 POWER STEERING OIL
PUMP REMOVAL/INSTALLATION.)
Note
• Position and secure the PIS oil pump out of the way with a rope.
7. Remove the AIC compressor with the pipes still connected. (See 07-11-6 AlC COMPRESSOR REMOVAL/
INSTALLATION.)
Note
• Position and secure the AIC compressor out of the way with rope or wire.
8. Remove the order indicated in the table.

10. Adjust the drive belt deflection. (See 01-10B-4 DRIVE BELT ADJUSTMENT [WL-C, WE-C].)
11. Bleed air in the fuel line. (See 01-14B-4 AFTER REPAIR PROCEDURE [WL-C, WE-C].)
12. Start the engine and
(1) Inspect the engine oil, engine coolant, and fuel leakage.
(2) Inspect the idle speed.
13. Perform a road test.
01-108-19
J..-_-,3 mil
53.9-76.4 {5.50-7.79, 39.S-56.3}

DBG110BWB91
ICooling fan Engine

(See 01-108-20 Engine Removal/Installation Note.)
Engine Removal/Installation Note

1. Install the SST to the cylinder head by using bolt
(99784 1020 or M1 OX1.2S, ST, length 20mm
{0.79 in}) as shown.
Tightening torque
43.1-60.S N·m {4.40-6.10 kgf·m, 31.S-44.S
ft.lbf}
2. Suspend the engine using the SST.
DBG110BWB89
01-108-20
ENGINE DISASSEMBLY/ASSEMBLY [WL-C, WE-C]
dcf011000000w06
1. Remove the intake-air system. (See 01-138-3 INTAKE-AIR SYSTEM REMOVAUINSTALLATION [WL-C, WE-
C].)
2. Remove the exhaust system. (See 01-158-2 EXHAUST SYSTEM REMOVAUINSTALLATION [WL-C, WE-C].)
3. Remove the oil cooler. (See 01-118-4 OIL COOLER REMOVAUINSTALLATION [WL-C, WE-C].)
5. Assemble in the reverse order of disassembly.
1 Drive belt
11.8-17.6 {1.2-1.8, 9-13}
2 Generator
6
(See 01-17-5 Generator Installation Note.)
3 Idler
37.3-S2.0
4 AlC compressor bracket {3.8-S.3,
5 Engine mount 28-38}
6 Oil pressure switch

(See 01-118-2 OIL PRESSURE INSPECTION [WL-
C, WE-C].)
7 Water pump pulley
{3.8-S.3, 38-S1
18.6-2S.S {3.9-S.2,
28-38}
{1.9-2.6,14-18} 29-37}
N·m {kgf·m, ft-lbf}
DBG110BWB88
ENGINE TUNE-UP [WL-C, WE-C]

dcfO 11 002000w04
Engine Tune-up Preparation
1. Start the engine and warm up completely.
2. Verify that the gear is in neutral position.
3. Verify that the accelerator pedal is released.
4. Turn off the AlC switch. (if equipped)
5. Turn off all electrical loads.
6. Verify that no DTC is present.
DBG110BWBA01
01-108-21
Idle Speed Inspection
1. Perform "Engine Tune-up Preparation". (See 01-108-21 Engine Tune-up Preparation.)
Note
• Idle speed is not adjustable.
• Idle speed verification requires current diagnostic tool.
2. Verify that the idling speed (current diagnostic tool: RPM PID) is within the specification using the current
diagnostic tool function.
Specification
No load: 695-745 rpm
AlC ON: 725-775 rpm
• If not as specified, inspect the following parts.

APP sensor
ECT sensor
CMP sensor
CKP sensor
Fuel pressure sensor
Fuel injector
Supply pump
• If the parts are normal, replace the PCM.
Correction Procedure
MAF correction
Using PDS/IDS
Note
• Perform this procedure after replacing the MAF/IAT sensor No.2 or at the recommended interval as
described under "E.G.R. system" in "SCHEDULED MAINTENANCE."

2. After the vehicle is identified, select the following items from the initial screen of the PDS/IDS.
1. Select the "Powertrain".
2. Select the "Engine Checks".
1. Select "All Tests and Calibrations".
3. Then, select the "Learning", "MAF Correction" and perform procedures according to directions on the PDS/IDS
screen.
4. Perform the MAF correction according to the directions on the PDS/IDS screen.
UsingWDS
Note
• Perform this procedure after replacing the MAF sensor/lAT sensor No.2 or at the recommended interval as
described under "E.G.R. system" in "SCHEDULED MAINTENANCE:'

2. Set up the WDS (including the vehicle recognition).
5. Select the "Learning".
6. Select the "MAF Correction" and perform procedures according to directions on the WDS screen.
7. Perform the MAF correction according to the directions on the WDS screen.
01-108-22
Without using current diagnostic tool
Note
completed.
1. Short the DLC-2 terminal TEN to body ground

using a jumper wire.
2. Short circuit the DLC-2 terminal TEN five times JUMPER

within 5 s. WIRE
GND1
DBG102BWB301
01-108-23
ENGINE TUNE-UP[WL-C, WE-C (AT)]
idO 11 099800600
Engine Tune-up Preparation
1. Start the engine and warm up completely.
2. Verify that the selector lever is in P position.
3. Verify that the accelerator pedal is released.
4. Turn off the AlC switch. (if equipped)
6. Verify that no DTC is present.
arnffw00001573
01-108-24
Idle Speed Inspection

Note
• Idle speed is not adjustable.
• Idle speed verification requires PDS/IDS.
2. Verify that the idling speed (PDS/IDS: RPM PID) is within the specification using the PDS/IDS function.
Specification
No load: 725-775 rpm
AlC ON: 725-775 rpm
• If not as specified, inspect the following parts.

APP sensor
ECT sensor
CMP sensor
CKP sensor
Fuel pressure sensor
Fuel injector
Supply pump
• If the parts are normal, replace the PCM.
Correction Procedure
MAF correction
Using PDSIIDS
Note
• Perform this procedure after replacing the MAF/IAT sensor No.2 or at the recommended interval as
described under "E.G.A. system" in "SCHEDULED MAINTENANCE."

2. After the vehicle is identified, select the following items from the initial screen of the PDS/IDS.
3. Then, select the "Learning", "MAF Correction" and perform procedures according to directions on the PDS/IDS
screen.
4. Perform the MAF correction according to the directions on the PDS/IDS screen.
01-108-25
Without using PDS/IDS
Note
completed.
1. Short the OLC terminal TEN to body ground using

a jumper wi're.
arnffw00001558
2. Short circuit the OLC terminal TEN five times

within 5 s.
JUMPER
FEN WIRE
GND
BODY GROUND
DLe
IG-
arnffw00001559
01-108-26
01-11B LUBRICATION [WL-C, WE-C]

LOCATION INDEX [WL-C, WE-C] ..... 01-11B-1 OIL COOLER REMOVAU
OIL PRESSURE INSPECTION INSTALLATION [WL-C, WE-C] ...... . 01-11 B-4
[WL-C, WE-C] .................... 01-11B-2 OIL COOLER BODY INSPECTION
ENGINE OIL LEVEL INSPECTION [WL-C, WE-C] ................... . 01-11B-5
[WL-C, WE-C] . . . . . . . . . . . . . . . . . . . . 01-11 B-2 OIL PAN REMOVAUINSTALLATION
ENGINE OIL REPLACEMENT [WL-C, WE-C] .................... 01-11 B-5
[WL-C, WE-C] .................... 01-11B-3 OIL PUMP REMOVAU
OIL FILTER REPLACEMENT INSTALLATION [WL-C, WE-C] ...... . 01-11B-7
[WL-C, WE-C] .................... 01-11B-3 OIL PUMP INSPECTION
[WL-C, WE-C] .................... 01-11 B-1 0
LOCATION INDEX [WL-C, WE-C]
DBG110BWB78
1 Oil pressure switch 3 Oil filter

(See 01-118-2 OIL PRESSURE INSPECTION [WL- (See 01-118-3 OIL FILTER REPLACEMENT [WL-C,
C, WE-C].) WE-C).)
2 Oil level gauge 4 Oil cooler
(See 01-118-2 ENGINE OIL LEVEL INSPECTION (See 01-118-4 OIL COOLER REMOVAU
[WL-C, WE-C).) INSTALLATION [WL-C, WE-C].)
(See 01-118-3 ENGINE OIL REPLACEMENT [WL- (See 01-118-5 OIL COOLER 80DY INSPECTION
C, WE-C].) [WL-C, WE-C].)
01-118-1
5 Oil pan 7 Oil pump component

(See 01-11 B-5 OIL PAN REMOVAUINSTALLATION (See 01-11 B-7 OIL PUMP REMOVAU
[WL-C, WE-C].) INSTALLATION [WL-C, WE-C].)
6 Oil strainer (See 01-11B-10 OIL PUMP INSPECTION [WL-C,
(See 01-11B-7 OIL PUMP REMOVAU WE-C].)
INSTALLATION [WL-C, WE-CJ.)
OIL PRESSURE INSPECTION [WL-C, WE-C]

dcf01111400Ow02
Warning
• Continuous exposure with USED engine oil has caused skin cancer in laboratory mice. Protect
your skin by washing with soap and water immediately after this work.
• When the engine and the oil are hot, they can badly burn. Turn off the engine and wait until they
are cool.
1. Remove the oil pressure switch.

2. Screw the SST into the oil pressure switch
installation hole.
3. Warm up the engine to normal operating
temperature.
4. Run the engine at the specified speed, and note
the gauge readings.
Note
• The oil pressure can vary with oil viscosity
and temperature.
Oil pressure [2,500 rpm]

410-570 kPa {4.19-5.81 kgf/cm 2,59.6-
82.6 psi}
5. If the pressure is not as specified, inspect for the cause and repair or replace as necessary.
6. Stop the engine and wait until it becomes cool.
7. Remove the SST.
8. Apply silicone sealant to the oil pressure switch
threads as shown.
9. Install the oil pressure switch before the sealant
hardens.
Tightening torque
u
11.8-17.6 N·m {1.2-1.8 kgf.m, 9-13 ft·lbf}
10. Start the engine and inspect for oil leakage.

4.0-6.0 mm
{0.160-0.23 in}
I~I
DBG111AWB102
ENGINE OIL LEVEL INSPECTION [WL-C, WE-C]

dcf011114001w03
1. Position the vehicle on level ground.

2. Warm up the engine to normal operating temperature and stop it.
3. Wait for five minutes.
4. Remove the dipstick and inspect for oil level and condition. Verify that the oil level is within the F and L marks on
the dipstick.
5. Add or replace oil if necessary.
01-118-2
ENGINE OIL REPLACEMENT [WL-C, WE-C]
dcf011114001w04
Warning
• When the engine and the engine oil are hot, they can badly burn. Don't burn yourself with either.
• A vehicle that is lifted but not securely supported on safety stands is dangerous. It can slip or fall,
causing death or serious injury. Never work around or under a lifted vehicle if it is not securely
supported on safety stands.
• Continuous exposure with USED engine oil has caused skin cancer in laboratory mice. Protect
your skin by washing with soap and water immediately after this work.

2. Remove the oil filler cap and the oil pan drain plug.
3. Drain the oil into a container.
4. Install the drain plug by using a new washer.
Tightening torque
29.4-41.2 N·m {3.00-4.20 kgf.m, 21.7-30.3 ft.lbf}
5. Refill the engine oil with the specified type and amount of engine oil.
6. Refit the oil filler cap.
7. Run the engine and inspect for oil leakage.
8. Inspect the oil level and add oil if necessary. (See 01-118-2 ENGINE OIL LEVEL INSPECTION [WL-C, WE-C].)
Note
• The actual oil level may very from the specified capacity in some cases.

Item Specification
Grade API CO/CE/CF-4 or ACEA 81/83/85
Viscosity (SAE) 5W-30, 1OW-3~
Oil capacity (approx. quantity)

Oil and oil filter replacement: 7.0 {7.4 US qt, 6.2 Imp qt}
OIL FILTER REPLACEMENT [WL-C, WE-C]

dcf011114300w02
1. Remove the oil filter by using the filter wrench.
2. Use a clean rag to wipe off the mounting surface
on the oil filter body.
3. Apply engine oil to the O-ring and tighten the filter
according to the installation directions on the side
of the oil filter using the filter wrench.
4. Start the engine and inspect for oil leakage.
5. Inspect for the oil level and add oil if necessary.
(See 01-118-2 ENGINE OIL LEVEL
INSPECTION [WL-C, WE-C].)(See 01-118-3
ENGINE OIL REPLACEMENT [WL-C, WE-C].)
DBG111AWB1R3
01-118-3
OIL COOLER REMOVAL/INSTALLATION [WL-C, WE-C]
dcf01111470Ow03

3. Remove the turbocharger. (See 01-158-2 EXHAUST SYSTEM REMOVAUINSTALLATION [WL-C, WE-C].)
4. Remove the oil filter. (See 01-118-3 OIL FILTER REPLACEMENT [WL-C, WE-C].)
5. Remove in the order shown in the figure.
7. Fill the radiator with the specified amount and type of engine coolant. (See 01-128-3 ENGINE COOLANT
REPLACEMENT [WL-C, WE-C].)
8. Inspect the engine oil level. (See 01-118-2 ENGINE OIL LEVEL INSPECTION [WL-C, WE-C].)
9. Start the engine and inspect for engine coolant leakage.
-.....,."...
18.6-25.5 {1.9-2.6, 14-18}
&---191
DBG111AWB104
1 Dipstick pipe Oil cooler body

4
(See 01-11 B-4 Oil Cooler Body Installation Note.)
2 Radiator hose
5 Oil cooler
3 Thermostat case
Oil Cooler Body Installation Note

• Tighten the mounting bolts and nuts in the order
shown.
DBG111AWB105
01-118-4
OIL COOLER BODY INSPECTION [WL-C, WE-C]
dcf011114700w04
• Measure the spring free length. Replace the spring if necessary.
Standard free length

Bypass valve spring: 36.7 mm {1.44 in}
Pressure control valve spring: 54.7 mm
rnn
{2.15 in} BYPASS VALVE SPRING
~ 0
PRESSURE CONTROL VALVE SPRING
rnn~[ID
OIL PAN REMOVAL/INSTALLATION [WL-C, WE-C]

2. Drain the engine oil. (See 01-11 B-3 ENGINE OIL REPLACEMENT [WL-C, WE-C).)
3. Remove the under cover.
4. Remove the front stabilizer. (See 02-13-16 FRONT STABILIZER AND TENSION ROD REMOVAU
INSTALLATION [4x2 (EXCEPT Hi-Rider)].) (See 02-13-17 FRONT STABILIZER REMOVAUINSTALLATION
[Hi-Rider,4x4].)
5. Disconnect the center link on the left side of the vehicle. (See 06-14-10 STEERING GEAR AND LINKAGE
REMOVAUINSTALLATION.)
8. Fill with the specified amount and type of engine oil. (See 01-11 B-3 ENGINE OIL REPLACEMENT [WL-C, WE-
C].)
9. Start the engine and inspect for engine oil leakage.
54.9-80.4
{5.6-8.1,40.5-59.3}
~ ®
I
APPLY SCREW LOCK AGENT
94.2-115.7
{9.5-11.8, 68.8-85.3}
7.8-10.8 N·m
{80-110 kgf·cm, 70-95 in·lbf}

DBG110BWB76
1 Front crossmember 3 Oil pan

2 Rear crossmember (4x4) (See 01-118-6 Oil Pan Removal Note.)
(See 01-118-6 Rear Crossmember Removal Note.) (See 01-118-7 Oil Pan Installation Note.)
01-118-5
Rear Crossmember Removal Note
1. Set the transmission jack on the front differential.
DBG110BWB77
2. Remove the bolts and nuts indicated in the figure.
DBG110BWB83
Oil Pan Removal Note

1. Remove the oil pan mounting bolts.
Caution
• Pry tools can easily scratch the cylinder block and oil pan contact surfaces. Prying off the oil pan
can also easily bend the oil pan flange.
2. Use a separate tool to separate the oil pan.
B3E0111W008
01-118-6
Oil Pan Installation Note
Caution
!o'
sealant from the bolt threads. Tightening
tv@l=j=E
bolt hole damage.
~ OLD SEALANT
1. Apply silicone sealant to the oil pan along the

inside of the bolt holes and overlap the ends.
o ...____...:::P~
o~
...
~O~----.;.O
Thickness
02.0-3.0 mm {0.OB-0.11 in}
2. Tighten the oil pan bolts A as indicated in the

figure.
A
passes.
o o o o o
DBG110AEBRB7
OIL PUMP REMOVAUINSTALLATION [WL-C, WE-C]

dcf011114100w03
2. Drain the engine oil. (See 01-11B-3 ENGINE OIL REPLACEMENT [WL-C, WE-C).)
3. Remove the under cover.
4. Remove the oil pan. (See 01-11B-5 OIL PAN REMOVAUINSTALLATION [WL-C, WE-C].)
5. Remove the timing belt. (See 01-10B-7 TIMING BELT REMOVAUINSTALLATION [WL-C, WE-C].)
6. Remove the crankshaft pulley. (See 01-10B-16 FRONT OIL SEAL REPLACEMENT [WL-C, WE-C].)
9. Fill with the specified amount and type of engine oil. (See 01-11 B-3 ENGINE OIL REPLACEMENT [WL-C, WE-
C).)
10. Start the engine and inspect for engine oil leakage.
01-118-7
8.8-12.7 N·m
{90-129 kgf·cm,
78-112 in·lbf}
7.8-10.8 N·m
{81-110 kgf·cm,
18.6-25.5
{1.9-2.6,14-18}
7.9-10.8 N·m
{81-110 kgf·cm,
70-95 in·lbf}
DBG111BWB99
1 Fuel injection pump pulley 6 Oil pump cover

2 Timing gear cover (8ee01-118-9 Oil Pump Cover Installation Note)
(8ee 01-118-8 Timing Gear Cover Removal Note) 7 Driven gear
(8ee01-11 8-9 Timing Gear Cover Installation Note) 8 Plug
3 Oil strainer 9 Plunger spring
4 Oil pipe 10 Control plunger
(8ee01-118-9 Oil Pipe Installation Note)
11 Oil pump body
5 Oil pump
Timing Gear Cover Removal Note

1. Remove the timing gear cover by using a
separator tool.
SEPARATOR TOOL
( "
DBG110AEB044
01-118-8
2. Remove the oil seal by using a screwdriver
protected with a rag,
Oil Pump Cover Installation Note

shown.
Oil Pipe Installation Note

shown.
DBG110AEBR89
Timing Gear Cover Installation Note

shown.
Thickness
~2.0-3.0 mm {O.079-0.118 in}
DBG110BEB071
01-118-9
2. Tithe bolts in two or three steps in the order
shown.
oil seal. .'

hammer. SUPPLY PUMP O.0-0.40mm
OIL SEAL {O.O-O.015 in}
measure the distance between the end of the IPUWi"MI
FRONT OIL SEAL
Front oil seal press-in amount IP"i,II'lCt,1I

0.0-0.40 mm {0.0-0.015 in} OIL SEAL

0.0-0.40 mm {0.0-0.015 in}
DBG111BWB98
OIL PUMP INSPECTION [WL-C, WE-C]

dcf01111410Ow04
1. Measure the following clearance. .

replace the gear and/or pump body.

0.10-0.19 mm {0.0040-0.0074 in}

0.20 mm {0.0079 in}
DBG110AEB101

0.04-0.09 mm {0.0016-0.0035 in}

0.15 mm {0.0059 in}
DBG110AEB102
2. Measure the free length of plunger spring .

replace the plunger spring.

43.8 mm {1.72 in}
DBG110AEB103
01-118-10
01-128 COOLING SYSTEM [WL-C, WE-C]

COOLING SYSTEM COOLANT RESERVE TANK
LOCATION INDEX [WL-C, WE-C] .... 01-128-1 REMOVALIINSTALLATION
COOLING SYSTEM [WL-C, WE-C] . ................... . 01-128-6
SERVICE WARNINGS RADIATOR REMOVALI
[WL-C, WE-C] . ................... 01-128-2 INSTALLATION [WL-C, WE-C] ...... . 01-128-6
ENGINE COOLANT THERMOSTAT REMOVALI
LEVEL INSPECTION [WL-C, WE-C] .. 01-128-2 INSTALLATION [WL-C, WE-C] ...... . 01-128-7
ENGINE COOLANT THERMOSTAT INSPECTION
PROTECTION INSPECTION [WL-C, WE-C] ................... . 01-128-8
[WL-C, WE-C] ..... ............... 01-128-2 COOLING FAN REMOVALI
ENGINE COOLANT INSTALLATION [WL-C, WE-C] ...... . 01-128-8
REPLACEMENT [WL-C, WE-C] ...... 01-128-3 COOLING FAN INSPECTION
ENGINE COOLANT LEAKAGE [WL-C, WE-C] ................... . 01-128-8
INSPECTION [WL-C, WE-C] . ........ 01-128-5 WATER PUMP REMOVALI
COOLING SYSTEM CAP INSTALLATION [WL-C, WE-C] ...... . 01-128-9
INSPECTION [WL-C, WE-C] . ........ 01-128-5
COOLING SYSTEM LOCATION INDEX [WL-C, WE-C]

dcf011200000w03
DBG112BWB702
1 Cooling system cap 4 Thermostat

(See 01-128-5 COOLING SYSTEM CAP (See 01-128-7 THERMOSTAT REMOVAU
INSPECTION [WL-C, WE-C].) INSTALLATION [WL-C, WE-C).)
2 Coolant reserve tank (See 01-128-8 THERMOSTAT INSPECTION [WL-
(See 01-128-6 COOLANT RESERVE TANK C, WE-C).)
REMOVAUINSTALLATION [WL-C, WE-C].) 5 Water pump
. 3 Radiator (See 01-128-9 WATER PUMP REMOVAU
(See 01-128-6 RADIATOR REMOVAU INSTALLATION [WL-C, WE-C).)
INSTALLATION [WL-C, WE-C).) 6 Cooling fan
(See 01-128-8 COOLING FAN REMOVAU
INSTALLATION [WL-C, WE-C])
(See 01-128-8 COOLING FAN INSPECTION [WL-
C, WE-C).)
01-128-1
COOLING SYSTEM SERVICE WARNINGS [WL-C, WE-C]

dcf01120000Ow04
Warning
• Never remove the cooling system cap while the engine is running, or when the engine and radiator
are hot. Scalding coolant and steam may shoot out and cause serious injury. It may also damage
the engine and cooling system.
• Turn off the engine and wait until it is cool. Even then, be very careful when removing the cap.
Wrap a thick cloth around it and slowly turn it counterclockwise to the first stop. Step back while
the pressure escapes.
• When you are sure all the pressure is gone, press down on the cap using the cloth, turn it, and
remove it.
ENGINE COOLANT LEVEL INSPECTION [WL-C, WE-C]

dcf011215001w05
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 PROTECTION INSPECTION [WL-C, WE-C]

dcf011215001w06
1. Measure the coolant temperature and specific gravity using a thermometer and a hydrometer.
Caution
• Use engine coolant at a concentration that meets the environmental conditions in which the
vehicle is driven, otherwise engine damage could occur.
• The engine has aluminum parts and must be protected by an ethylene-glycol-based coolant to
prevent corrosion and freezing.
• Do not use coolants containing Alcohol, Methanol, Borate or Silicate. These coolants could
damage the cooling system.
• Use only soft (demineralized) water in the coolant mixture. Water that contains minerals will cut
down on the coolant's effectiveness.
• Engine coolant damages paint. If engine coolant does get on a painted surface, rinse it off quickly.
Note
• If the "FL22" mark is shown on or near the cooling system cap, use FL22 type engine coolant.
• FL22 type engine coolant is shipped as a
diluted solution (55% coolant, 45% water).
Use the solution as is when replacing
coolant.
IFL22lWi
E5U112ZW5010
( "
01-128-2
2. Determine the coolant protection level by referring
SPECIFIC COOLANT PROTECTION
to the graph shown. GRAVITY (EXCEPT FL22 TYPE ENGINE COOLANT)
• If the coolant protection level is not correct,
1.10
add water or coolant. I-- I"-----
1.09
I"----- I"-----
1.08 r--... r--.....
-...... .......... ..........
t--- t- 1"-----......
1.07
r- .......... r---- .......... .......... 55%
--
1.06 ..........
I"'- t--- I"'- 45%
1.05
r-- ............ 35%
1.04
1.03
1.02
1.01
1.00
o 5 10 15 20 25 30 35 40 45 50
(32) (41) (50) (59) (6S) (77) (S6) (95) (104) (113) (122)
COOLANT TEMPERATURE °c {OF}

DDA 112ZW4003
ENGINE COOLANT REPLACEMENT [WL-C, WE-C]

dcf011215001w07
Warning
• Never remove the cooling system cap while the engine is running, or when the engine and radiator
are hot. Scalding coolant and steam may shoot out and cause serious injury. It may also damage
the engine and cooling system.
• When you are sure all the pressure is gone, press down on the cap using the cloth, turn it, and
remove it.
Caution
• Use engine coolant at a concentration that meets the environmental conditions in which the
vehicle is driven, otherwise engine damage could occur.
• The engine has aluminum parts and must be protected by an ethylene-glycol-based coolant to
prevent corrosion and freezing.
• Do not use coolants containing Alcohol, Methanol, Borate or Silicate. These coolants could
damage the cooling system.
• Use only soft (demineralized) water in the coolant mixture. Water that contains minerals will cut
down on the coolant's effectiveness.
• Engine coolant damages paint. If engine coolant does get on a painted surface, rinse it off quickly.
Note
• If the "FL22" mark is shown on or near the cooling system cap, use FL22 type engine coolant.
• FL22 type engine coolant is shipped as a
diluted solution (55% coolant, 45% water).
Use the solution as is when replacing
coolant.
Engine coolant capacity (approx. quantity)

9.4 L{9.9 US qt, 8.3 Imp qt} IFL22Wl
1. Remove the coolant reserve tank with the hose
still connected.
2. Remove the coolant reserve tank cap and drain
the engine coolant from the coolant reserve tank.
E5U112ZW5010
01-128-3
3. Remove the cooling system cap.
COOLING
SYSTEM CAP
DBGl12AWB702
4. Loosen the radiator drain plug and drain the

engine coolant into a container.
5. Flush the cooling system with water until all traces
of color are gone.
6. Let the system drain completely.
7. Tighten the radiator drain plug.
DRAIN
8. Referring to the following chart, select the correct PLUG
volume percentage of the water and coolant.
DBGl12AWB101
Antifreeze solution mixture percentage (Except FL22 type engine coolant)

Engine coolant Volume percentage ('Yo)
Gravity at 20°C {68 OF}
protection Water Coolant
Above -16°C {3 OF} 65 35 1.057
Above -26°C {-15 OF} 55 45 1.072
Above -40°C {-40 OF} 45 55 1.086
9. Refill the coolant from the cooling system filler neck until it is close to the top of the cooling system filler neck.
10. Refill the coolant into the coolant reserve tank up to the F mark on the tank.
11. Install the cooling system cap.
Caution
• If the water temperature gauge rises too high, stop the engine and decrease the water temperature
to prevent overheating. Then, verify the malfunctioning part and repair or replace it.
12. Start the engine and warm up the engine by idling.

13. After the engine warms up, perform the following steps. At this time, be careful of the coolant temperature to
prevent overheating.
(1) Run the engine at approx. 2,500 rpm for 5 min.
(2) Run the engine at approx. 3,000 rpm for 5 s, then idle.
(3) Repeat step (2) 4-5 times.
14. Stop the engine, and inspect the coolant level after the coolant temperature decreases. If it is low, repeat steps
10-14.
15. Inspect for coolant leakage. (See 01-128-5 ENGINE COOLANT LEAKAGE INSPECTION [WL-C, WE-C].)
• If the coolant leaks, specify the malfunctioning part and repair or replace it.
01-128-4
ENGINE COOLANT LEAKAGE INSPECTION [WL-C, WE-C]
dcf011215001w08
Warning
• Removing the radiator cap while the engine is running, or when the engine and radiator are hot is
dangerous. Scalding coolant and steam may shoot out and cause serious injury. It may also
damage the engine and cooling system.
• When you're sure all the pressure is gone, press down on the cap still using the cloth, turn it, and
remove it.
1. Inspect the engine coolant level. (See 01-128-2 ENGINE COOLANT LEVEL INSPECTION [WL-C, WE-C).)
2. Remove the radiator cap.
3. Clean the installation parts of the cooling system cap.
4. Connect a radiator cap tester and the SST to the radiator filler neck.
5. Apply pressure to the radiator. ,------------------------,
Pressure
122 kPa {1.25 kgf/cm 2 , 17.7 psi}
Caution
• Applying more than 122 kPa {1.25 kgfl
cm 2 , 17.7 psi} can damage the hoses,
fittings, and other components, and
cause leakage.
6. Verify that the pressure is help. If not, inspect the DBG112BWB001

system for coolant leakage.
COOLING SYSTEM CAP INSPECTION [WL-C, WE-C]

dcf011215201w02
Warning
• Removing the radiator cap while the engine is running, or when the engine and radiator are hot is
dangerous. Scalding coolant and steam may shoot out and cause serious injury. It may also
damage the engine and cooling system.
• When you're sure all the pressure is gone, press down on the cap still using the cloth, turn it, and
remove it.
1. Clean the cooling system cap and the sealed part.

2. Inspect the cooling system cap for cracks or everted seal.
• If there is any malfunction, replace the cooling system cap.
3. Attach the cooling system cap to the SST and a ,------------------------,
radiator cap tester.
4. Hold the cooling system cap downward and apply
pressure gradually. Verify that the pressure is held
stable for 10 s.
• If the pressure is not held stable, replace the
cooling system cap.
Cooling system cap valve opening pressure

93.2-122.6 kPa {O.95-1.25 kgflcm 2 , 13.5- COOLING SYSTEM CAP
17.8 psi}
DBG112BWB002
01-128-5
COOLANT RESERVE TANK REMOVAUINSTALLATION [WL-C, WE-C]
dcf01121503Ow02
Warning
• Remove and install all parts when the engine is cold, otherwise they can cause severe burns or
serious injury.
I 1 IHose
DBG112BWB701
RADIATOR REMOVAUINSTALLATION [WL-C, WE-C]

dcf01121520Ow02
Warning
serious injury.
1. Drain the engine coolant. (See 01-128-3 ENGINE COOLANT REPLACEMENT [WL-C, WE-C).)
4. Fill the radiator with the specified amount and
type of engine coolant.(See 01-128-3 ENGINE
COOLANT REPLACEMENT [WL-C, WE-C].)
1 Radiator upper seal
2 Radiator hose
3 Lower radiator cowling
4 Radiator cowling
5 Radiator
~
(lr
DBG112AWB102
i"
01-128-6
THERMOSTAT REMOVAUINSTALLATION [WL-C, WE-C]
dcf011215171w03
Warning
serious injury.
1. drain the engine coolant.(See 01-128-3 ENGINE COOLANT REPLACEMENT [WL-C, WE-C].)
type of engine coolant. (See 01-128-3 ENGINE
1 Dipstick pipe
2 Lower radiator hose
3 Thermostat cover
4 Thermostat
(See 01-128-7 Thermostat Installation Note.)
18.6-25.5
{1.90-2.60.
13.8-18.8}
"",.5
{80-110 kgf·cm.
"·'.0
N·m {kgf·m. tt·lbf}
DBG112BWB003
Thermostat Installation Note

• Install the thermostat into the thermostat cover,
aligning the projection on the gasket to the GASKET
thermostat cover as shown.
THERMOSTAT COVER
DBG112AWB104
01-128-7
THERMOSTAT INSPECTION [WL-C, WE-C)
dcf011215171w04
Warning
• During inspection, the thermostat and water are extremely hot and they can badly burn. Do not
touch the thermostat and water directly.
Inspect the thermostat for the following and replace as necessary.

• Open valve in room temperature
• Opening temperature and lift of valve
Initial-opening temperature and lift of the valve

80-84 °C {176-183 OF}
Full open temperature

95°C {203 OF}
Full open life

8.5 mm {0.33 in} or more
COOLING FAN REMOVAL/INSTALLATION [WL-C, WE-C)

dcf01121514Ow03
1. Remove the drive belt.
2. Remove in the order indication in the table.
4. Adjust the drive belt (generator) deflection. (See
01-10B-4 DRIVE BELT ADJUSTMENT [WL-C,
WE-C].)
ICooling fan
18.6-25.5 N·m {1.90-2.60 kgf·m, 13.8-18.8}
DBG112BWB004
COOLING FAN INSPECTION [WL-C, WE-C)

dcf01121514Ow04
1. Rotate the cooling fan by hand and inspect for
abnormal noise and looseness. Replace the
cooling fan id necessary. (See 01-12A-8
COOLING FAN REMOVAL/INSTALLATION [WL-
3].)
DBG112AWB107
01-128-8
WATER PUMP REMOVAUINSTALLATION [WL-C, WE-C]
dcf011215010w02
1. Remove the cooling fan. (See 01-128-8 COOLING FAN REMOVAL/INSTALLATION [WL-C, WE-C].)
2. Drain the engine coolant. (See 01-128-3 ENGINE COOLANT REPLACEMENT [WL-C, WE-C]
3. Remove in the reverse order of removal.
type of engine coolant. (See 01-128-3 ENGINE
IWater pump
18.6-25.5 {1.90-2.60,
13.8-18.8} N·m {kgf.m, ft·lbf}
01-128-9
01-138 INTAKE-AIR SYSTEM [WL-C, WE-C]

INTAKE-AIR SYSTEM VACUUM CHECK VALVE
LOCATION INDEX [WL-C, WE-C] .... 01-13B-1 INSPECTION [WL-C, WE-C] . ....... . 01-13B-8
INTAKE-AIR SYSTEM VACUUM HOSE GLOW PLUG REMOVAU
ROUTING DIAGRAM [WL-C, WE-C] .. 01-13B-2 INSTALLATION [WL-C, WE-C] ...... . 01-13B-8
INTAKE-AIR SYSTEM GLOW PLUG INSPECTION
REMOVAUINSTALLATION [WL-C, WE-C] . .................... 01-13B-9
[WL-C, WE-C] . ................... 01-13B-3 GLOW PLUG RELAY REMOVAU
AIR CLEANER ELEMENT INSTALLATION [WL-C, WE-C] ...... . 01-13B-9
INSPECTION [WL-C, WE-C] ........ 01-13B-5 GLOW PLUG RELAY
TURBOCHARGER INSPECTION [WL-C, WE-C] ......... 01-13B-9
INSPECTION [WL-C, WE-C] ........ 01-13B-5 GLOW PLUG CORD
GUIDE BLADE ACTUATOR INSPECTION [WL-C, WE-C] ......... 01-13B-11
INSPECTION [WL-C, WE-C] ........ 01-13B-6 ACCELERATOR PEDAL
VARIABLE BOOST CONTROL (VBC) COMPONENT REMOVAU
SOLENOID VALVE INSPECTION INSTALLATION [WL-C, WE-C] ...... . 01-13B-11
[WL-C, WE-C] . ................... 01-13B-6 ACCELERATOR PEDAL
ADJUSTMENT [WL-C, WE-C] ........ 01-13B-12
INTAKE-AIR SYSTEM LOCATION INDEX [WL-C, WE-C]

dcf01130000Ow04
CD
DBG113BWB301
1 Intake-air system 4 Turbocharger

(See 01-13B-3INTAKE-AIR SYSTEM REMOVAU (See 01-13B-5 TURBOCHARGER INSPECTION
INSTALLATION [WL-C, WE-C].) [WL-C, WE-C].)
2 Air cleaner 5 Guide blade actuator
(See 01-13B-5 AIR CLEANER ELEMENT (See 01-13B-5 TURBOCHARGER INSPECTION
INSPECTION [WL-C, WE-C].) [WL-C, WE-C].)
3 Fresh-air duct 6 VBC solenoid valve
(See 01-13B-3INTAKE-AIR SYSTEM REMOVAU (See 01-13B-6 VARIABLE BOOST CONTROL
INSTALLATION [WL-C, WE-C].) (VBC) SOLENOID VALVE INSPECTION [WL-C,
WE-C].)
01-138-1
7 Vacuum check valve 11 Glow plug relay

(See 01-138-8 VACUUM CHECK VALVE (See 01-138-9 GLOW PLUG RELAY REMOVAU
INSPECTION [WL-C, WE-C).) INSTALLATION [WL-C, WE-C).)
8 Charge air cooler (See 01-138-9 GLOW PLUG RELAY INSPECTION
(See 01-138-3 INTAKE-AIR SYSTEM REMOVAU [WL-C, WE-C].)
INSTALLATION [WL-C, WE-C].) 12 Glow plug cord
9 Intake manifold (See 01-138-11 GLOW PLUG CORD INSPECTION
(See 01-138-3 INTAKE-AIR SYSTEM REMOVAU [WL-C, WE-C).)
INSTALLATION [WL-C, WE-C].) 13 Accelerator pedal component
10 Glow plug (See 01-138-11 ACCELERATOR PEDAL
(See 01-138-8 GLOW PLUG REMOVAU COMPONENT REMOVAUINSTALLATION [WL-C,
INSTALLATION [WL-C, WE-C].) WE-C].)
(See 01-138-9 GLOW PLUG INSPECTION [WL-C,
WE-C).)
INTAKE-AIR SYSTEM VACUUM HOSE ROUTING DIAGRAM [WL-C, WE-C]

dcf01130000OW05
VACUUM CHECK VALVE

AIR FILTER
VBC SOLENOID VALVE
EGRVALVE
INTAKE SHUTTER
SOLENOID VALVE
(HALF)
INTAKE SHUTTER
SOLENOID VALVE
(FULL)
EGR CONTROL INTAKE SHUTTER VALVE
SOLENOID VALVE
VACUUM PUMP
DBG113BWB305
01-138-2
INTAKE-AIR SYSTEM REMOVAUINSTALLATION [WL-C, WE-C]
dcf011300000w06
Warning
• A hot engine and intake-air system can cause severe burns. Turn off the engine and wait until they
are cool before removing the intake-air system.
Note
• If the MAF sensor is replaced, always perform each adjustment procedure using the following steps.
MAF sensor
STEP ACTION PAGE/CONDITION
Perform mass air flow (MAF) sensor data reset (See 01-408-22 MASS AIR FLOW (MAF) SENSOR DATA RESET
procedure. [WL-C, WE-C].)
2 Perform KOEO self-test procedure. (See 01-028-10 KOEO/KOER SELF TEST [WL-C, WE-C].)
3 Turn the engine switch to the off position.
4 Wait for 5 s.
5 Start the engine.
6 Perform KOER self-test procedure. (See 01-028-10 KOEO/KOER SELF TEST [WL-C, WE-C].)
7 Turn the engine switch to the off position.

01-138-3
19-25N·m
{2.0-2.5 kgf·m,
15-1S ft·lbf}
4.9 {50, 43}

~ ~.®\
6.9-9.S
{71-99,62-S6}
7
7.S-10.S
{SO-110,70-95}
~
7.8-10.S
{SO-110, 70-95}
7.S-10.S
{SO-11 0, 70-95}
6.9-9.S -----,~
{71-99,62-S6}
6
N·m {kgf.cm, in·lbf}
DBG113BWB312
1 MAF sensor/lAT sensor No.2 Fresh-air duct

6
2 Air intake hose (See 01-13B-5 Fresh-Air Duct Removal Note.)
3 Air cleaner cover 7 VBC solenoid valve
4 Air cleaner element 8 Vacuum check valve
5 Air cleaner case 9 Turbocharger air outlet hose
10 Turbocharger air outlet pipe
01-138-4
11 Charge air cooler inlet hose 17 Intake shutter valve

12 Charge air cooler outlet hose 18 EGR control solenoid valve bracket
13 Charge air cooler 19 Boost sensor/lAT sensor No.1
14 Charge air cooler air outlet pipe Intake manifold
20
15 Charge air cooler air outlet hose (See 01-13B-5 Intake Manifold Removal Note.)
16 Vacuum pipe
Fresh-Air Duct Removal Note

1. Remove the front mud guard. (See 09-10-9 FRONT FENDER PANEL REMOVAUINSTALLATION.)
Intake Manifold Removal Note

1. Set the fuel filter component slightly out of the way. (See 01-14B-9 FUEL FILTER REMOVAUINSTALLATION
[WL-C, WE-C].)
2. Remove the EGR valve and EGR pipe.
3. Remove the injection pipe. (See 01-14B-11 SUPPLY PUMP REMOVAL/INSTALLATION [WL-C, WE-C].)
4. Remove the common rail. (See 01-14B-11 SUPPLY PUMP REMOVAL/INSTALLATION [WL-C, WE-C].)
AIR CLEANER ELEMENT INSPECTION [WL-C, WE-C]

1. Remove the air cleaner element. (See 01-13B-3 INTAKE-AI R SYSTEM REMOVAL/INSTALLATION [WL-C,
WE-C].)
2. Inspect the following items:
• If there is any malfunction, clean or replace the air cleaner element.
• If the replacement interval has come, replace the air cleaner element.
Is the air cleaner element soiled, damaged, or bent?
- Are the air cleaner case and the air cleaner element correctly sealed?
- Is the correct air cleaner element installed?
TURBOCHARGER INSPECTION [WL-C, WE-C]

dcf011313700w02
Note
• Before performing the following inspection, make sure to follow the procedure as indicated in the
troubleshooting flowchart. (See 00-00-5 Troubleshooting Procedure.)
Compressor Wheel Inspection

2. Remove the air intake hose between the air cleaner and the turbocharger. (See 01-13B-3INTAKE-AIR
SYSTEM REMOVAL/INSTALLATION [WL-C, WE-C].)
3. Visually inspect the compressor wheel from view A and verify that all fins are free from damage, cracks or
bends.
• If there are damaged fins, cracks or bends,
replace the turbocharger. (See 01-15B-2
EXHAUST SYSTEM REMOVAU
Note
• To make the inspection easier, set a small
mirror as shown in the figure and use a ~
~A"
penlight.
• If the compressor wheel is interfering with
the compressor housing, it is likely that the MIRROR
fin edges are cracked, damaged, or bent.
DBG113BWB306
• If the compressor wheel is damaged, check
the following before replacing the
turbocharger to avoid reoccurrence of the malfunction.
Foreign material in intake air/exhaust system.
- Oil pipe clogging.
01-138-5
Turbine Wheel Inspection
2. Remove the jOint pipe. (See 01-158-2 EXHAUST SYSTEM REMOVAUINSTALLATION [WL-C, WE-C].)
3. Visually inspect the turbine wheel from view B and verify that all fins are free from damage, cracks or bends. f . '
• If there are damaged fins, cracks or bends,

replace the turbocharger. (See 01-15B-2
EXHAUST SYSTEM REMOVAU
Note
• To make the inspection easier, set a small
mirror as shown in the figure and use a
penlight.
• If the turbine wheel is interfering with the
turbine housing, it is likely that the fin edges
are cracked, damaged, or bent.
DBG113BWB307
• If the turbine wheel is damaged, check the
following before replacing the turbocharger
to avoid reoccurrence of the malfunction.
Foreign material in intake air/exhaust system.
- Oil pipe clogging.
GUIDE BLADE ACTUATOR INSPECTION [WL-C, WE-C]

dcf01131370Ow03
1. Disconnect the vacuum hose from the guide blade actuator.

2. Connect the vacuum pump to the guide blade .-----------------------,
actuator.
3. Apply vacuum and verify that the rod moves as
specified.
• If not as specified, replace the turbocharger.
Specification
Vacuum (kPa {mmHg, inHg}) Rod movement
Below -14.2 {-1 06, -4.19} Starts to move
Above -47.3 {-355, -14.0} Fully pulled
VARIABLE BOOST CONTROL (VBC) SOLENOID VALVE INSPECTION [WL-C, WE-C]

dcf011318748w01
Note
• Perform the following test only when directed.
Airflow Inspection
2. Remove the VBC solenoid valve. (See 01-13B-3INTAKE-AIR SYSTEM REMOVAUINSTALLATION [WL-C,
WE-C].)
3. Inspect airflow between the ports under the following conditions.
• If not as specified, replace the VBC solenoid valve. (See 01-13B-3 INTAKE-AIR SYSTEM REMOVAU
• If as specified, carry out the "Resistance Inspection".
r----------------------,
0--0 : Continuity ()::=(): Airflow

Terminal Port
Step
A B A B
1 0 -0
,.... ,....
2 B+ GROUND
DBG113BWB322 DBG113BWB311
01-138-6
Resistance Inspection
2. Disconnect the VBC solenoid valve connector. (See 01-13B-3INTAKE-AIR SYSTEM REMOVAU
3. Measure the resistance between the VBC solenoid valve terminals using an ohmmeter.
• If not as specified, replace the VBC solenoid valve. (See 01-13B-3 INTAKE-AIR SYSTEM REMOVAU
• If VBC solenoid valve is okay, perform the
"Circuit Open/Short Inspection".
VBC SOLENOID VALVE
VBC solenoid valve resistance
12.6-15.4 ohms [20-30 °C {67-a6 OF}]
DBG113BWB315
Circuit Open/Short Inspection

1. Disconnect the PCM connector. (See 01-40B-9 PCM REMOVAUINSTALLATION [WL-C, WE-C].)
2. Inspect the following wiring harness for open or
short circuit (continuity Inspection). VBC SOLENOID VALVE
WIRING HARNESS-SIDE MAIN RELAY
CONNECTOR
rc1AI
1m]
DBG113BWB316
PCM
124 123 122 121 120 119 118 117 116 115 114 113 112 111 110 109 108 107 106 105 104 103 102 101
148 147 146 145 144 143 142 141 140 139 138 137 136 135 134 133 132 131 130 129 128 127 126 125
172 171 170 169 168 167 166 165 164 163 162 161 160 159 158 157 156 155 154 153 152 151 150 149
196 195 194 193 192 191 190 189 188 187 186 185 184 183 182 181 180 179 178 177 176 175 174 173
DBG113BWB319
Open circuit
• If there is no continuity, the circuit is open. Repair or replace the wiring harness.
- VBC solenoid valve terminal A and main relay terminal D
- VBC solenoid valve terminal Band PCM terminal 178
Short circuit
• If there is continuity, the circuit is shorted. Repair or replace the wiring harness.
VBC solenoid valve terminal A and body ground
VBC solenoid valve terminal B and power supply
VBC solenoid valve terminal B and body ground
01-138-7
VACUUM CHECK VALVE INSPECTION [WL-C, WE-C]
dcf011318748w02
1. Remove the vacuum check valve. (See 01-13B-3 INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [WL-C,
WE-C].)
2. Blow through port A and verify that the airflows
from port B. "
• If not as specified, replace the vacuum check
valve. (See 01-13B-3 INTAKE-AIR SYSTEM
REMOVAUINSTALLATION [WL-C, WE-C].)
3. Blow through port B and verify that the air does A B
not flow from port A.
• If not as specified, replace the vacuum check
valve. (See 01-13B-3INTAKE-AIR SYSTEM
A6E40102015
GLOW PLUG REMOVAL/INSTALLATION [WL-C, WE-C]

dcf011318601w03
Warning
Caution
• Do not damage the heated section of the glow plug.
• Do not reuse a glow plug that has been dropped over a height of 10 cm {3.9 in}, even when there
are no scratches and resistance is normal (approx. 1.4 ohms [20°C {58 OF}] (Reference value».
• Do not remove the glow plug unless you are replacing it.

3. Remove the common rail. (See 01-14B-11 SUPPLY PUMP REMOVAUINSTALLATION [WL-C, WE-C].)
1 Glow plug cord
2 Glow plug
(See 01-138-8 Glow Plug Removal Note.)
(See 01-138-8 Glow Plug Installation Note.)

15-20
{1.6-2.0,
12-14}
DBG113BWB309
Glow Plug Removal Note

1. When removing the glow plug, first loosen it at least one pitch using a tool, then loosen by hand.
Glow Plug Installation Note

1. Tighten the glow plug it at least one pitch by hand, and continue tightening with a tool.
01-138-8
GLOW PLUG INSPECTION [WL-C, WE-C)
dcf011318601w04
1. Remove the glow plug cord. (See 01-138-8 GLOW PLUG REMOVAUINSTALLATION [WL-C, WE-C].)
2. Measure the resistance between the glow plug terminal and the cylinder head (body ground) using an
ohmmeter.
• If not as specified, replace the glow plug. (See 01-138-8 GLOW PLUG REMOVAUINSTALLATION [WL-C,
WE-C].)
Glow plug resistance (Reference value)

Approx. 1.4 ohms [20°C {68°F}]
DBG113BWB310
GLOW PLUG RELAY REMOVAUINSTALLATION [WL-C, WE-C)

2. Remove the glow plug relay.
3. Install the glow plug relay.
4. Connect the negative battery cable.
DBG113AWB208
GLOW PLUG RELAY INSPECTION [WL-C, WE-C)

dcf011318611w05
Note
System Inspection
1. Carry out the "Glow Plug Control Operation Inspection". (See 01-038-62 Glow Plug Control Operation
Inspection. )
2. If not as specified, perform the further inspection for the glow plug relay.
01-138-9
Continuity Inspection
1. Remove the glow plug relay. (See 01-138-9 GLOW PLUG RELAY REMOVAUINSTALLATION [WL-C, WE-C].)
2. Verify the continuity between the glow plug relay
terminals.
0-0 : Continuity
Terminal
Step
A B C D
1 Q 0
2 B+ GND 0 -0
CHU0921W006 DBG113AWB310
• If not as indicated in the table, replace the
glow plug relay. (See 01-138-8 GLOW PLUG
• If as specified but the "System Inspection" is failed, perform the "Circuit Open/Short Inspection".

1. Disconnect the PCM connector. (See 01-408-9 PCM REMOVAL/INSTALLATION [WL-C, WE-C].)
2. Inspect the following wiring harnesses for an
open or short circuit. (Continuity inspection) GLOW PLUG RELAY
W
n n
D MAIN RELAY
Q:;
o rcfA1
A - B
~
I~~I
DBG113AWB311
PCM
219 218 217 216 215 214 213 212 211 210 209 208 207
202 201
232 231 230 229 228 227 226 225 224 223 222 221 220
204 203
245 244 243 242 241 240 239 238 237 236 235 234 233
206 205
258 257 256 255 254 253 252 251 250 249 248 247 246
DBG113BWB318
Open circuit
• If there is no continuity in the following wiring harnesses, there is an open circuit. Repair or replace the
wiring harness.
Glow plug relay terminal A and PCM terminal 182
Glow plug relay terminal 8 and main relay terminal D
- Glow plug relay terminal C and power supply
- Glow plug relay terminal D and PCM terminal 227
- Glow plug relay terminal D and glow plug cord
Short circuit
• If there is continuity in the following wiring harnesses, there is a short circuit. Repair or replace the wiring
harness.
Glow plug relay terminal A and power supply
Glow plug relay terminal A and body ground
Glow plug relay terminal 8 and body ground
Glow plug relay terminal C and body ground
Glow plug relay terminal D and body ground
01-138-10
GLOW PLUG CORD INSPECTION [WL-C, WE-C]
dcf011318611w06
1. Remove the glow plug cord from glow plug. (See 01-13B-8 GLOW PLUG REMOVAUINSTALLATION [WL-C,
WE-C).)
2. Verify that the glow plug cord is not broken or bent.
Note
• When inspecting for continuity in the glow plug cord, do not let the uncovered parts (A) come into contact
with other parts and be shorted.
3. Verify there is continuity at both ends of the glow

plug cord.
• If there is no continuity, replace the glow plug
cord. (See 01-13B-8 GLOW PLUG
REMOVAL/INSTALLATION [WL-C, WE-C].)
DBG113BWB314
ACCELERATOR PEDAL COMPONENT REMOVAL/INSTALLATION [WL-C, WE-C]

dcf011341600w03
2. Set the power brake unit slightly out of the way. (See 04-11-10 POWER BRAKE UNIT REMOVAU
INSTALLATION.)
3. Set the clutch master cylinder slightly out of the way. (See 05-10-6 CLUTCH MASTER CYLINDER REMOVAU
INSTALLATION.)
4. Remove the column cover and steering shaft. (See 06-14-6 STEERING WHEEL AND COLUMN REMOVAU
INSTALLATION.)
1 Neutral switch connector
2 Brake switch connector
3 Idle switch connector
4 APP sensor connector
5 Spring pin
6 Clevis pin
Pedal component (See 01-13B-11 Pedal
7
Component Installation Note.) 18.6-25.5
DBG113AWB305
Pedal Component Installation Note

• Carry out the "BRAKE PEDAL INSPECTION" procedure after installing the pedal component. (See 04-11-6
BRAKE SWITCH INSPECTION.)
• Carry out the "CLUTCH PEDAL ADJUSTMENT" procedure after installing the pedal component. (See 05-10-4
CLUTCH PEDAL ADJUSTMENT.)
01-138-11
ACCELERATOR PEDAL COMPONENT REMOVAUINSTALLATION[WL-C, WE-C (AT)]
id011398807300
2. Remove the 4x4 control module. (4x4) (See 03-18-S 4x4 CONTROL MODULE REMOVAL/INSTALLATION [AT.
(SRSSS)].)
iii
4
2 Idle switch connector
3 APP sensor connector
4 Spring pin
5 Clevis pin
18.6-25.5
Pedal component (See 01-13B-1 Pedal Component {1.90-2.60,
6
Installation Note.) 13.8-18.8}
Nm {kgfm, ftlbf}
arnffw00001574
Pedal Component Installation Note

1. Carry out the "BRAKE PEDAL INSPECTION" procedure after installing the pedal component.
01-138-11a
ACCELERATOR PEDAL ADJUSTMENT [WL-C, WE-C]
dcf01134160OW04
c\
Caution
• Adjusting the APP sensor and idle switch unnecessarily may adversely affect engine control.
Therefore, adjust APP sensor and/or idle switch only when it is replaced.
-,.
Note
• Perform the following adjustment only when directed.
1. Temporarily install the APP sensor and the idle switch to the pedal assembly and verify that the APP sensor
installation bolts and idle switch locknut are lightly tightened.
2. Connect the APP sensor and the idle switch connector.
4. Verify that the voltage between APP sensor
terminals A and 0 is between 4.9 to 5.1 V (target APP SENSOR
value 5.0 V). WIRING HARNESS-SIDE CONNECTOR
r=::=l
1:0 1 C 1 B 1 A:IJ
I~~ I
DBG140AWB311
5. Set the current diagnostic tool and monitor APp,

APP2 and IVS PIDs.(See01-02B-8 PID/DATA
Monitor And Record Procedure)
APP SENSOR PCM
DBG140BWB314
6. Adjust the APP sensor installation position so that

the APP and APP2 PIDs value is between 0.5 to APP SENSOR
0.7 V (target value 0.6 V) with the accelerator
pedal fully released, then tighten the APP sensor
installation bolts
DBG140AWB332
01-138-12
7. While fully depressing the accelerator pedal until
it contacts the stopper rubber, adjust the stopper
rubber installation position so that the APP and
APP2 value is between 3.4 to 3.8 V (target value
3.6 V).
8. While slowly depressing the accelerator pedal by

hand, adjust the idle switch installation position so
that the IVS PIO turns from ON to OFF with the
APP and APP2 value is between 1.0 to 1.2 V
(target value 1.1 V), then tighten the idle switch
locknut.
DBGl13AWB701
Tightening torque
13.7-17.6 N·m {1.40-1.79 kgf·m, 10.2-12.9
ft·lbf}
9. Verify that the IVS PIO turns from OFF to ON

when the accelerator pedal is full released.
10. While depressing the accelerator pedal again,
verify that the IVS PIO turns from ON to OFF with IDLE SWITCH
the APP and APP2 PIOs value is between 1.0 to
LOCKNUT
1.2 V (target value 1.1 V).
DBG113AWB702
01-138-13
01-148 FUEL SYSTEM [WL-C, WE-C]

FUEL SYSTEM SEDIMENTOR SWITCH
CI LOCATION INDEX [WL-C, WE-C] ....

FUEL SYSTEM
DIAGRAM [WL-C, WE-C] ...........
01-148-1
01-148-3
INSPECTION [WL-C, WE-C] ......... 01-148-10
SUPPLY PUMP REMOVAU
INSTALLATION [WL-C, WE-C] ...... . 01-148-11
8EFORE REPAIR SUPPLY PUMP
PROCEDURE [WL-C, WE-C] ........ 01-148-3 INSPECTION [WL-C, WE-C] . ....... . 01-148-13
AFTER REPAIR FUEL METERING
PROCEDURE [WL-C, WE-C] ........ 01-148-4 VALVE INSPECTION [WL-C, WE-C] ... 01-148-13
FUEL TANK REMOVAU FUEL-INLET FILTER
INSTALLATION [WL-C, WE-C] ....... 01-148-4 REMOVAUINSTALLATION
FUEL TANK [WL-C, WE-C] ..................... 01-148-14
INSPECTION [WL-C, WE-C] ........ 01-148-8 COMMON RAIL
FUEL FILTER REMOVAU INSPECTION [WL-C, WE-C] ........ . 01-148-14
INSTALLATION [WL-C, WE-C] ....... 01-148-9 FUEL INJECTOR REMOVAU
SEDIMENTOR INSTALLATION [WL-C, WE-C] ...... . 01-148-15
WATER DRAINING [WL-C, WE-C] .... 01-148-9 FUEL INJECTOR
INSPECTION [WL-C, WE-C] ......... 01-148-16
FUEL SYSTEM LOCATION INDEX [WL-C, WE-C]

dcf011400000w05
Engine Room Side
DBG114BWB301
1 Fuel filter 3 Supply pump

(See 01-148-9 FUEL FILTER REMOVAU (See 01-148-11 SUPPLY PUMP REMOVAU
INSTALLATION [WL-C, WE-C].) INSTALLATION [WL-C, WE-C).)
(See 01-148-9 SEDIMENTOR WATER DRAINING (See 01-148-13 SUPPLY PUMP INSPECTION [WL-
[WL-C, WE-C).) C, WE-C].)
2 Sedimentor switch 4 Fuel metering valve
(See 01-148-10 SEDIMENTOR SWITCH (See 01-148-13 FUEL METERING VALVE
INSPECTION [WL-C, WE-C].) INSPECTION [WL-C, WE-C].)
01-148-1
5 Fuel-inlet filter 7 Fuel injector

(See 01-14B-14 FUEL-INLET FILTER REMOVAU (See 01-14B-15 FUEL INJECTOR REMOVAU
INSTALLATION [WL-C, WE-C].) INSTALLATION [WL-C, WE-C].)
6 Common rail (See 01-14B-16 FUEL INJECTOR INSPECTION
I..
/
(See 01-14B-14 COMMON RAIL INSPECTION [WL-C, WE-C].)

[WL-C, WE-C].) 8 Check valve
Fuel Tank Side

Double cab 4x2(except Hi-Rider), Stretch cab 4x2 (with rear access system (except Hi-Rider))
DBG114BWB331
Regular cab, Double cab 4x4, stretch cab 4x4 (with rear access system), Hi-Rider
DBG114BWB330
Fuel tank I 2 IFuel gauge sender unit

(See 01-14B-4 FUEL TANK REMOVAU
(See 01-14B-8 FUEL TANK INSPECTION [WL-C,
WE-C].)
01-148-2
FUEL SYSTEM DIAGRAM [WL-C, WE-C]
dcf011400000w06
- *:TOPCM
-----.. : FUEL FLOW
BEFORE REPAIR PROCEDURE [WL-C, WE-C]

dcf011400000w07
Warning
• Fuel line spills and leads are dangerous. Fuel can ignite and cause serious injuries or death and
damage. Fuel can also irritate skin and eyes. To prevent this, always complete the following "Fuel
Line Safety Procedures".
• A person charged with static electricity could cause a fire or explosion, resulting in death or
serious injury. Before performing work on the fuel system, discharge static electricity by touching
the vehicle body.
Fuel Line Safety Procedures

1. Avoid fuel line spills and leaks by completing the following procedures.
(1) Remove the fuel-filler cap and release the pressure in the fuel tank.
(2) When disconnecting a fuel line hose, wrap a rag around it to protect against fuel leakage.
(3) Plug the hose after removal.
01-148-3
AFTER REPAIR PROCEDURE [WL-C, WE-C]
dcf01140000Dw08
Warning
damage. When installing the fuel hose, observe "Fuel Hose Installation" described below.
Caution
• If fuel does not pass through the fuel filter, foreign material may have penetrated in the supply
pump, and this may cause a malfunction resulting in damage to the supply pump. Therefore, do
not install the fuel hoses (main and return side) in reverse. When installing the fuel hose, always
follow the Fuel Hose Installation Note in the Workshop Manual and perform the procedure. (See
01-14B-13 Fuel Hose Installation Note.)
Fuel Line Air Bleeding
Caution
• Continuously cranking the engine for over 30 s can damage the battery and the starter.
1. Continue cranking the engine for 30 s and stop for 5-10 s until the engine starts.
Fuel Hose Installation

1. Verify that there is no damage or deformation on the fuel hose and fuel pipe when installing.
2. When installing the fuel hose connected to the supply pump, verify each side (main and return), and install at
the specified position. (See 01-14B-13 Fuel Hose Installation Note.)
FUEL TANK REMOVAL/INSTALLATION [WL-C, WE-C]

dcf011442110w03
Warning
• Repairing a fuel tank that has not been properly steam cleaned can be dangerous. Explosion or
fire may cause death or serious injury. Always properly steam clean a fuel tank before repairing it.
• A person charged with static electricity could cause a fire or explosion, resulting in death or
serious injury. Before draining fuel, make sure to discharge static electricity by touching the
vehicle body.

2. Complete the "BEFORE REPAIR PROCEDURE" (See01-14B-3 BEFORE REPAIR PROCEDURE [WL-C, WE-
C].)
3. Remove the drain plug and drain the fuel from the fuel tank.
4. Remove the rear flap.
5. Remove in the reverse order indicated in the table.
6. Install in the reverse order indicated of removal.
7. Complete the "AFTER REPAIR PROCEDURE". (See 01-14B-4 AFTER REPAIR PROCEDURE [WL-C, WE-C].)
01-148-4
1.1-2.1 N·m {11-22 kgf·cm,

10-19 in·lbf}
7.9-10.7 N·m {80-110 kgf·cm,

69.5-95.4 in·lbf}
L~ .
-~
~(Q)
9-+A
~1 1
fftJi~~
2.5-3.5 N·m
{25-36 kgf.cm, 0
22-26 in·lbf}
}m
26-32 {2.6-3.3,
19-23}
32-46 {3.2-4.7, 24-33}
N·m {kgf.m, tt·lbf}
DBG114BWB332
01-148-5
1.1-2.1 N·m 1.1-2.1 N'm {11-22 kgf·cm.
{11-22 kgf·cm. 10-19 in·lbf}
10-19 in·lbf}
7.9-10.7 N·m {80-110 kgf·cm.

69.5-95.4 in·lbf}
~1 1
fQ'~~
2.5-3.5 N·m
{25-36 kgf.cm.
22-26 in·lbf}
10
2.5-4.6 N·m
{25-47 kgf·cm.
22-40 in·lbf}
11.8-16.6 N·m
32-46 {3.2-4.7.
24-33}
32-46 {3.2-4.7. 24-33}
N·m {kgf·m. ft.lbf}
DBG114BWB333
1 Joint hose (See 01-14B-7 Joint Hose Installation 6 Evaporative hose (See 01-14B-7 Evaporative Hose
Note.) Installation Note.)
2 Breather hose (See 01-14B-7 Breather Hose 7 Fuel gauge sender unit
Installation Note.) 8 Rollover valve
3 Under guard 9 Fuel-filler pipe
4 Fuel hose 10 Dust cover
(See 01-14B-7 Fuel Hose Installation Note.)
11 Fuel inlet pipe
5 Fuel tank
01-148-6
Evaporative Hose Installation Note
• Fit each hose onto the respective fittings within the specification, and install clamps as shown.
(~:~~m;"
Length
Evaporative hose: 25 mm {O.98 in}
;'l
BREATHER HOSE
Fuel Hose Installation Note

• Fit each onto the respective fittings within the specification, and install camp as shown.
Length
Fuel hose: 25mm {O.98 in}
'\ 1,10 mm {0.39 in}
ptfl~~l (
FUEL HOSE
DBG114AWB015
Breather Hose Installation Note

• Fit each hose onto the respective fittings within the specification, and install clamp as shown.
Length
Breather hose: 25 mm {O.98 in}
'\ 1,10 mm {0.39 in}
ptfl~~l (
EVAPORATIVE HOSE
DBG114AWB016
Joint Hose Installation Note

• Fit the joint hose onto the respective fittings within the specification, and install clamps as shown.
Length
Joint hose: 35 {1.4 in]
912 mm 912 mm
{0.3S 0.47 in} {0.3S 0.47 in}
VIEWA VIEWS
DBG114AWB017
01-148-7
FUEL TANK INSPECTION [WL-C, WE-C]
dcf011442110w04
Note
• This inspection is for the two rollover valves and the check valve (two-way) which is integrated in the fuel
hose.
1. Follow "BEFORE REPAIR PROCEDURE" before performing any work operations to prevent fuel from spilling
from the fuel system. (See 01-14B-3 BEFORE REPAIR PROCEDURE [WL-C, WE-C).)
3. Remove the fuel tank. (See 01-14B-4 FUEL TANK REMOVAUINSTALLATION [WL-C, WE-C].)
4. Plug the fuel pipe of the fuel gauge sender unit. .
5. Plug port C.
6. Connect the pump to port B.
7. Level the fuel tank.
CHECK VALVE
(TWO-WAY)
DBG114AWB060
8. Apply pressure of 5-6 kPa {38-45 mmHg,

1.5-1.7 inHg} to port B. ROLLOVER VALVE FUEL HOSE
(1) Verify there is airflow from port A.
• If there is no airflow, replace the two ROLLOVER VALVE
rollover valves and the three fuel hoses
indicated in the figure.
CHECK VALVE
(TWO-WAY)
DBG114AWB303
9. Apply pressure of -5- -6 kPa {-38- -45

mmHg, -1.5--1.7 inHg} to port B. ROLLOVER VALVE FUEL HOSE
• If there is no airflow, replace the two rollover
valves and the three fuel hoses indicated in ROLLOVER VALVE
the figure.
CHECK VALVE
(TWO-WAY)
DBG114AWB303
• If there is airflow, turn the fuel tank upside-

down and proceed to next step.
FUEL GAUGE
SENDER UNIT
ROLLOVER VALVE C
DBG 114AWB061
01-148-8
10. Apply pressure of 5-6 kPa {38-45 mmHg,
1.5-1.7 inHg} to port B. ROLLOVER VALVE FUEL HOSE
(1) Verify there is no airflow from port A.
• If there is airflow, replace the two rollover ROLLOVER VALVE
valves and the three fuel hoses indicated
in the figure.
CHECK VALVE
(TWO-WAY)
DBG114AWB303
FUEL FILTER REMOVAL/INSTALLATION [WL-C, WE-C]

dcf011420490w02

2. Complete the "BEFORE REPAIR PROCEDURE". (See 01-14B-3 BEFORE REPAIR PROCEDURE [WL-C,
WE-C].)
4. Assemble in the reverse order of removal.
6. Bleed air from the fuel filter.
7. Start the engine and verify that fuel does not leak from the fuel system.
8. If fuel leaks, reassemble the fuel filter. ,---------------------,
~~
1 Connector
2 Fuel hose
3 Priming pump
Fuel filter
4
(See 01-148-9 Fuel Filter Assembly Note.)
Sedimentor switch
14.7-19.6
{1.5D-1.99, ~
10.9-14.4} 4
5 (See 01-148-9 Sedimentor Switch Assembly
Note.)
6 Drain plug
4.4-5.4 N·m
{45-55 kgf·cm,
39-47 in·lbf}
N'm {kgf·m, tt·lbf}
DBG114AWB038
Sedimentor Switch Assembly Note

• Apply a small amount of fuel to a new O-ring. Tighten the sedimentor switch enough to the fuel filter by hand.
Fuel Filter Assembly Note

• Apply a small amount of fuel to the fuel filter O-ring.Tighten the fuel filter approx. 3/4 by hand after the O-ring
contacts the priming pump.
SEDIMENTOR WATER DRAINING [WL-C, WE-C]

dcf011413080w02

WE-C].)
3. Loosen the drain plug located at the bottom of the fuel filter.
4. Pump the priming pump and drain the water.
5. After all the water has been drained, tighten the drain plug.
7. Reconnect the negative battery cable.
01-148-9
SEDIMENTOR SWITCH INSPECTION [WL-C, WE-C]
dcf011413081w02
Note

2. Drain fuel from the fuel filter. (See 01-14B-9 SEDIMENTOR WATER DRAINING [WL-C, WE-C].)
3. Remove the sedimentor switch.
4. Inspect continuity of the sedimentor switch by
using an ohmmeter.
Float Continuity
Up Yes
Down No
DBG114AWB019
5. If not as specified, replace the sedimentor switch.

If as specified, inspect following: SEDIMENTOR SWITCH
Open circuit
• Ground circuit (Sedimentor switch connector A B
terminal B and body ground)
• Power circuit (Sedimentor switch connector
terminal A and engine switch connector
terminal C)
HARNESS SIDE CONNECTOR
(VIEW FROM TERMINAL SIDE)
DBG114AWB020
Short circuit
ENGINE SWITCH
• Ground circuit (Sedimentor switch connector
terminal B and body ground to power circuit)
• Power circuit (Sedimentor switch connector
IArBI
terminal A and engine switch connector
terminal C to ground)
6.
7.
8.
9.
Repair or replace faulty areas.
Install the sedimentor switch.
Reconnect the negative battery cable.
Bleed air from the fuel filter.
tffij
HARNESS SIDE CONNECTOR
(VIEW FROM TERMINAL SIDE)
DBG 114AWB021
01-148-10
SUPPLY PUMP REMOVAL/INSTALLATION [WL-C, WE-C]
dcf011413350w01
Caution
• Fuel line spills and leakage on the parts are dangerous. Fuel can ignite and also deteriorate the
parts. To prevent this, always cover the mouths of the removed parts in the fuel system with rags
to soak up the fuel.
• To prevent the fuel injection pipe from clogging, be careful that foreigo material has not entered
the pipe. Also, be sure to tighten the bolts with the specified tightening torque when installing the
fuel injection pipe.
• To prevent fuel leakage, follow the procedure indicated in the workshop manual when removing
and installing the fuel injector.
• The fuel injection pipe can be removed and reinstalled up to five times. Be sure to record in the
service record when removing and installing the fuel injection pipe. If removing it for the sixth
time, be sure to replace it with a new one.
• Always carry out the cleaning process before carrying out any repairs to the fuel injection system
components to prevent foreign matter ingress to the components.
• If fuel does not pass through the fuel filter, foreign material may have penetrated in the supply
pump, and this may cause a malfunction resulting in damage to the supply pump. Therefore, do
not install the fuel hoses (main and return side) in reverse. When installing the fuel hose, always
follow the Fuel Hose Installation Note in the Workshop Manual and perform the procedure. (See
01-14B-13 Fuel Hose Installation Note.)

WE-C].)
3. Remove the battery and battery tray. (See 01-17-2 BATTERY REMOVAL/INSTALLATION.)
4. Remove the battery carrier. \. ~
5. Set the fuel filter component slightly out of the '----"'F>-'-
way. (See 01-14B-9 FUEL FILTER REMOVAL/ 6.9-9.8 N·m
INSTALLATION [WL-C, WE-C].) {71-99 kgf·cm,
62-86 in·lbf}
8. Complete the "AFTER REPAIR PROCEDURE".
(See 01-14B-4 AFTER REPAIR PROCEDURE
15.7-22.5 -~IIoG/'~
[WL-C, WE-C].) {1.61-2.29,
11.6-16.5}
DBG114BWB705
9. Start the engine and verify that fuel does not leak
from the fuel system.
Injection pipe
1
(See 01-148-12 Injection Pipe Removal Note.)
2 Common real 7.8-10.8 N·m
Fuel hose
3
(See 01-148-13 FuelHose Installation Note.)
4 Connector
Timing belt cover (See 01-108-9 Timing 8elt Cover
5 Installation Note.)
Supply pump
6 (See 01-148-12 Supply Pump Pulley Removal
Note.)
{1.90-2.60,
13.8-18.8}
N·m {kgf·m, It·lbf}
DBG114BWB002
01-148-11
Injection Pipe Removal Note
Caution
• If the fuel injector inlet connector is not locked against rotation when removing the injection pipe,
it may loosen and cause fuel leakage.
1. Lock the fuel injector inlet connector against

rotation.
2. Loosen the flare nut on the injection pipe while
being careful not to allow the inlet connector to
rotate.
FLARE NUT
FUEL INJECTOR
DBG114BWB304
Supply Pump Pulley Removal Note

1. Removal the two supply pump pulley mounting bolts.
2. Loosen the fuel injection pump pulley locknut.
3. Remove the pulley with the SST.
\(~(
0'-'
t:JJ
/
FUEL INJECTION
PUMP PULLY
~OCKNUT
DBG114BWB023
01-148-12
Fuel Hose Installation Note
• Install the fuel main hose and fuel return hose as shown in the figure.
CHECK VALVE
FUEL INJECTOR
COMMON RAIL
SEDIMENTOR SWITCH
SUPPLY PUMP
DBG114BWB787
SUPPLY PUMP INSPECTION [WL-C, WE-C]

dcf011413350w02
Caution
• The supply pump is sealed to maintain proper function. Special tools and testers are required
when disassembling the supply pump. Disassembling the supply pump without special tools and
testers will cause a malfunction.
• Consult authorized parts distributor for repair if any of the injection pump inner parts are possibly
malfunctioning.
1. Supply pump inner parts

2. Fuel metering valve
3. Fuel temperature sensor
FUEL METERING VALVE INSPECTION [WL-C, WE-C]

dcf011413350w03
Caution
• The supply pump is sealed to maintain proper function. Special tools and testers are required
when disassembling the supply pump. Disassembling the supply pump without special tools and
testers will cause a malfunction.
01-148-13
2. Disconnect the fuel metering valve connector.
3. Measure the resistance between the fuel
metering valve terminals using an ohmmeter.
• If not as specified, repair the supply pump.
(See 01-14B-13 SUPPLY PUMP
• If as specified, carry out the "Circuit Open/
Short Inspection".
Specification
Ambient temperature (OC eF}) Resistance (ohm)
FUEL METERING
20 {68} 2.6-3.15
VALVE
DBG114BWB012

1. Inspect for an open or short circuit in the following wiring harnesses.
• If there is an open or short circuit, repair or replace wiring harnesses.
Open circuit
• Power circuit (fuel metering valve terminal A and main relay terminal D)
• Ground circuit (fuel metering valve terminal Band PCM terminal 179)
Short circuit
• Fuel metering valve terminal A and main relay terminal D to ground
FUEL-INLET FILTER REMOVAUINSTALLATION [WL-C, WE-C]

dcf01141335Ow04

2. Disconnect the fuel hose connecting to the fuel-inlet pipe.
3. Remove in the eye bolt. ,-----------------------,
Note
• The fuel-inlet filter cannot be removed as it is
crimped to the eye bolt. GASKET iii
4. If there is any malfunction, clean the fuel-inlet
filter.
23-27N·m
{2.4-2.7 kgf·m,
17-19 ft·lbf}
DBG114BWB004
COMMON RAIL INSPECTION [WL-C, WE-C]

dcf011413151w01
Caution
• Do not remove the fuel pressure sensor nor the fuel pressure limiter from the common rail. Since
fuel pressure in the common rail is extremely high, the fuel pressure sensor, fuel pressure limiter,
or the common rail can be damaged, leading to fuel leakage if any of them are removed.
1. Visually inspect the common rail for damage and cracks. Also verify that there is no extreme rust which will
cause fuel leakage.
• If either is observed, replace the common rail.
01-148-14
FUEL INJECTOR REMOVAUINSTALLATION [WL-C, WE-C]
dcf011413250w01
Caution
• Fuel line spills and leakage on the parts are dangerous. Fuel can ignite and also deteriorate the
parts. To prevent this, always cover the mouths of the removed parts in the fuel system with rags
to soak up the fuel.
• To prevent the fuel injection pipe from clogging, be careful that foreign material has not entered
the pipe. Also, be sure to tighten the bolts with the specified tightening torque when installing the
fuel injection pipe.
• To prevent fuel leakage, follow the procedure indicated in the workshop manual when removing
and installing the fuel injector.
• The fuel injection pipe can be removed and reinstalled up to five times. Be sure to record in the
service record when removing and installing the fuel injection pipe. If removing it for the sixth
time, be sure to replace it with a new one.
• Always carry out the cleaning process before carrying out any repairs to the fuel injection system
components to prevent foreign matter ingress to the components.
Note
• Perform "FUEL INJECTOR CODE PROGRAM" after replacing fuel injector. (See 01-40B-21 FUEL
INJECTOR CODE PROGRAM [WL-C, WE-C].)

WE-C].)
3. Disconnect the CMP sensor connector.
4. Disconnect the ECT sensor connector.
5. Disconnect the fuel presser sensor connector.
6. Disconnect the fuel injector connector.
9. Complete the "AFTER REPAIR PROCEDURE".
21.0-26.0
(See 01-14B-4 AFTER REPAIR PROCEDURE {2.15-2.65, 21.0-26.0
[WL-C, WE-C].)
1 Fuel return hose
2 Fuel injection pipe
3 Injector bracket
4 Fuel injector
~4 ~
~I ~25_29
f£? {2.5-2.9,
=~~ll~~~~~~19-21}
-
~_
-'-N"-D.T= 9''''==\
..F __ ,...r=r . ...F~
~Cl
-=---
(tr
~I N·m {kgf·m, ft·lbf}
DBG114BWB001
01-148-15
FUEL INJECTOR INSPECTION [WL-C, WE-C]
dcf01141325OW02
Note

2. Disconnect the fuel injector connectors.
3. Measure the resistance of the fuel injector using
an ohmmeter.
• If not as specified, replace the fuel injector.
(See 01-148-15 FUEL INJECTOR
Short Inspection".
Resistance
Approx. 0.225 ohms
DBG114BWB010

1. Disconnect the PCM connector.
2. Inspect the following wiring harnesses for open or
FUEL INIJECTOR
short (continuity check). WIRING HARNESS-SIDE CONNECTOR
DBG114BWB011
PCM
DBG114BWB009
01-148-16
Open circuit
• If there is no continuity, the circuit is open. Repair or replace the wiring harness.
No.1 cylinder fuel injector terminal Band peM terminal 174.
No.1 cylinder fuel injector terminal A and peM terminal 125.
NO.3 cylinder fuel injector terminal A and peM terminal 101.
Short circuit
• If there is continuity, the circuit is short. Repair or replace the wiring harness.
No.1 cylinder fuel injector terminal B and body ground.
No.1 cylinder fuel injector terminal A and body ground.
NO.3 cylinder fuel injector terminal A and body ground.
No.1 cylinder fuel injector terminal B and power supply.
No.1 cylinder fuel injector terminal A and power supply.
01-148-17
01~15B EXHAUST SYSTEM [WL-C, WE-C]

EXHAUST SYSTEM EXHAUST SYSTEM
INSPECTION [WL-C, WE-C] . ........ 01-158-1 REMOVAUINSTALLATION
[WL-C, WE-C] ................... . 01-158-2
EXHAUST SYSTEM INSPECTION [WL-C, WE-C]

dcf011500000w03
1. Start the engine and inspect each exhaust system component for exhaust gas leakage.
• If leakage is found, repair or replace if necessary.
01-158-1
EXHAUST SYSTEM REMOVAUINSTALLATION [WL-C, WE-C]
dcf01150000Ow04
Warning
• When the engine and exhaust system are hot, they can cause severe burns or injury. Turn off the
engine and wait until they are cool before removing the exhaust system.

3. Remove the air cleaner. (See 01-138-3 INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [WL-C, WE-C].)
4. Remove the EGR cooler. (See 01-168-4 EGR SYSTEM REMOVAUINSTALLATION [WL-C, WE-C].)
7. Start the engine and:
(1) Inspect the exhaust gas leakage.
(2) If any servicing around the turbocharger is performed, inspect around the turbocharger for oil or engine
coolant leakage.
37-52 {3.8-5.3, 28-38}
19-25 {2.0-2.5, 15-18}

22-27 {2.3-2.7, 17-19} N·m {kgf·m, tt·lbf}
DBG115BWB001
1 Main silencer 6 Water pipe

2 Oxidation catalytic converter (See 01-158-3 Water Pipe Removal Note.)
(See 01-158-3 Water Pipe Installation Note.)
3 Front pipe
(See 01-158-3 Front Pipe Installation Note.) 7 Oil pipe
4 Exhaust manifold insulator 8 Oil hose (supply)
(See 01~158-3 Oil Hose (Supply) Installation Note.)
5 Turbocharger insulator
01-158-2
9 .1 Turbocharger 11 IExhaust manifold

10 Joint pipe
Water Pipe Removal Note

1. Drain the engine coolant before removing the water pipe. (See 01-12B-3 ENGINE COOLANT REPLACEMENT
[WL-C, WE-C].)
Oil Hose (Supply) Installation Note

1. Secure section A using a spanner.
2. Tighten the nut at B.
Tightening torque:
B, D: 14.7-20.6 N·m {150-210 kg.em, 131-
182 in.lbf}
3. Hold section C using pliers.

4. Tighten the nut at D.
Water Pipe Installation Note

1. Refill the engine coolant after Installing the water pipe. (See 01-12B-3 ENGINE COOLANT REPLACEMENT
[WL-C, WE-C].)
Front Pipe Installation Note

1. Temporarily tighten the nuts A.
Tightening torque:
A, B: 37-52 N·m {3.8-5.3 kg·m, 28-38
ft·lbf}
C: 19-25 N·m {2.0-2.5 kg·m, 15-18 ft·lbf}
2. Temporarily tighten the bolts Band C.

3. Completely tighten the nuts A.
4. Completely tighten the bolts Band C.
DBG115BWB002
01-158-3
01-168 EMISSION SYSTEM [WL-C, WE-C]

EMISSION SYSTEM EGR CONTROL SOLENOID VALVE
LOCATION INDEX [WL-C, WE-C] .... 01-168-1 INSPECTION [WL-C, WE-C] ........ . 01-168-6
EMISSION SYSTEM INTAKE SHUTTER SOLENOID VALVE
DIAGRAM [WL-C, WE-C] ........... 01-168-3 (HALF) INSPECTION [WL-C, WE-C] .. 01-168-6
EGR SYSTEM REMOVAL! INTAKE SHUTTER SOLENOID VALVE
INSTALLATION [WL-C, WE-C] ....... 01-168-4 (FULL) INSPECTION [WL-C, WE-C] .. 01-168-7
EGR VALVE INSPECTION INTAKE SHUTTER VALVE
[WL-C, WE-C] . ................... 01-168-5 INSPECTION [WL-C, WE-C] ........ . 01-168-7
EGR SOLENOID VALVE ROLLOVER VALVE INSPECTION
INSPECTION [WL-C, WE-C] ........ 01-168-5 [WL-C, WE-C] ................... . 01-168-8
EMISSION SYSTEM LOCATION INDEX [WL-C, WE-C]

dcf01160000Ow03
Engine Room Side
arnffw00000460
1 EGR valve 4 EGR solenoid valve

(See 01-168-4 EGR SYSTEM REMOVAU (See 01-168-5 EGR SOLENOID VALVE
INSTALLATION [WL-C, WE-C].) INSPECTION [WL-C, WE-C).)
(See 01-168-5 EGR VALVE INSPECTION [WL-C, 5 EGR control solenoid valve
WE-C].) (See 01-168-6 EGR CONTROL SOLENOID VALVE
2 EGR cooler INSPECTION [WL-C, WE-C].)
(See 01-168-4 EGR SYSTEM REMOVAU 6 Air filter
INSTALLATION [WL-C, WE-C).)
7 Intake shutter solenoid valve (half)
3 Intake shutter valve (See 01-168-6 INTAKE SHUTTER SOLENOID
(See 01-138-3 INTAKE-AIR SYSTEM REMOVAU VALVE (HALF) INSPECTION [WL-C, WE-C].)
(See 01-168-7 INTAKE SHUTTER VALVE 8 Intake shutter solenoid valve (full)
INSPECTION [WL-C, WE-C).) (See 01-168-7 INTAKE SHUTTER SOLENOID
VALVE (FULL) INSPECTION [WL-C, WE-C].)
01-168-1
9 Oxidation catalytic converter

(See 01-158-2 EXHAUST SYSTEM REMOVAU
Fuel Tank Side

DBG116BWB330
DBG116BWB331
Roliover valve
(See 01-168-8 ROLLOVER VALVE INSPECTION
[WL-C, WE-C].)
01-168-2
EMISSION SYSTEM DIAGRAM [WL-C, WE-C]
dcf01160000Ow04
EGR CONTORL SOLENOID VALVE
EGR SOLENOID VALVE
INTAKE SHUTTER SOLENOI J---lI-\YIO~

VALVE (HALF OPEN)

VALVE (FULL CLOSE)
-*:TOPCM
DBG116BWB332
01-168-3
EGR SYSTEM REMOVAUINSTALLATION [WL-C, WE-C]
dcf01160002Ow02

3; Install in the reverse order of removal.
19-25 {2.Q-2.5, 15-18}
DBG116BWB702
IEGR pipe 3 IEGR valve

2 EGR cooler
EGR system installation note

1. Temporarily tighten bolts and nuts in order of A to F.
01-168-4
2. Tighten the bolts and nuts in order of A to F.
TO FRONT
TO FRONT
DBG116BWB703
EGR VALVE INSPECTION [WL-C, WE-C]

dcf011620300w02
1. Inspect for airflow between 1 and 2 when vacuum is applied using a vacuum pump as shown in the figure.
• If not as specified, replace the EGR valve.
Specification
Vacuum
Airflow
kPa {mmHg, inHg}
Below -30.0- -36.6
Yes
{-226- -274,-8.90 - -10.8}
Except above No
DBG116AWB002
EGR SOLENOID VALVE INSPECTION [WL-C, WE-C]

dcf011618741w04

2. Monitor the following signals using the PID/data
monitor.
• EGR solenoid
• Mass air flow (MAF)
3. Using the "SEGRP" simulation function, verify that
the mass intake airflow amount changes.
• If the mass airflow amount does not change,
inspect the following:
EGR solenoid valve
Wiring harness and connector open
circuit (main relay-EGR solenoid valve-
DBG110BWBA01
PCM)
Vacuum hose disconnection or damage
4. Clear all DTCs stored in the PCM referring to the "AFTER REPAIR PROCEDURE".
01-168-5
EGR CONTROL SOLENOID VALVE INSPECTION [WL-C, WE-C]
dcf011618741w05

• If not as specified, replace the EGR control solenoid valve.
• If as specified, carry out the "Circuit Open/Short Inspection."
.-------------------------------------,
0=0 : Airflow
Terminal Port
~B:fTh
Step
A B A B C
r-..
1
~
c
2 B+ GND () :() A '---C::;:lJl~---.-.1
YTA4114Wl05
I ~~I
DBGl16BWB705

Open circuit
• Power circuit (EGR control solenoid valve terminal A and main relay terminal D)
• Ground circuit (EGR control solenoid valve terminal Band PCM terminal 177)
Short circuit
• EGR control solenoid valve terminal A and main relay terminal D to ground
INTAKE SHUTTER SOLENOID VALVE (HALF) INSPECTION [WL-C, WE-C]

dcf01160000Ow05

• If not as specified, replace the intake shutter valve (half).
• If as specified, carry out the "Circuit Open/Short Inspection:'
0=0 : Airflow B
Terminal Port
Step
A B A B C
1 () 0
2 B+ GND C 0 A
YTA4114Wl05
,,
,,,
,
,
L __________________________________________________________ 1 ,,
DBG116BWB704

Open circuit
.• Power circuit (intake shutter solenoid valve (half) terminal A and main relay terminal D)
• Ground circuit (intake shutter solenoid valve (half) terminal Band PCM terminal 152)
Short circuit
• Intake shutter solenoid valve (half) terminal A and main relay terminal D to ground
to,
01-168-6
INTAKE SHUTTER SOLENOID VALVE (FULL) INSPECTION [WL-C, WE-C]
dcf011600000w06
• If not as specified, replace the intake shutter valve (full).
• If as specified, carry out the "Circuit Open/Short Inspection."
0=0 : Airflow B
Terminal Port
Step
A 8 A 8 C
1
~ ~
2 B+ GND A
YTA4114W105 ,,,
,,
,,
,,
L __________________________________________________________ 1 ,
DBG116BWB704

Open circuit
• Power circuit (intake shutter solenoid valve (full) terminal A and main relay terminal D)
• Ground circuit (intake shutter solenoid valve (full) terminal Band PCM terminal 155)
Short circuit
• Intake shutter valve (full) terminal A and main relay terminal D to ground
INTAKE SHUTTER VALVE INSPECTION [WL-C, WE-C]

dcf011600000w07
1. Disconnect the vacuum hose from the intake shutter valve.

2. Connect a vacuum pump to port A. .-----------------------,
3. Apply vacuum and verify that the rod moves.
• If the rod does not move, replace the intake
shutter valve.
Specification (WL-C)
r----------Vac·uurn----------:----------------------------:
: kPa {mmHg, inHg} : Rod movement '
f----Seiow:::4 1:"3"0::"1~2} ----: --------Startto move -------:
: -Above-~25~3-f~ 190~ -~7 ~47} -: ---------Fully-pulle-ci --------:
L ____________________________ ~ ____________________________ ~
Specification (WE-C) DBG116BWB706

:----------Vac-uurn----------:----------------------------:
, , Rod movement '
: kPa {mmHg, inHg} : :
r---Below :::3.-6 1:"2T:"1~ 1}---: --------Start-to move -------:
:L -Above -~2i9-f~209~ -~8~24} -:• ---------Fully
____________________________ -pulled --------:
____________________________ ~
4. Connect a vacuum pump to port A and B.

5. Apply vacuum and verify that the rod moves.
• If the rod does not move, replace the intake
shutter valve.
Specification (WL-C)
,r----------------------------
Vacuum ----------------------------,'
:L ________________________________________________________
kPa {mmHg, inHg} Rod movement ~:
:L ________________________________________________________
Above -40 {-300, -11.8} Fully pulled ~
:
Specification (WE-C)
,r----------------------------
Vacuum ----------------------------,'
DBG116BWB707
: kPa {mmHg, inHg} Rod movement :
~---------------------------- ----------------------------~~
: Above -44 {-330, -13.0} Fully pulled
L ________________________________________________________
:
01-168-7
ROLLOVER VALVE INSPECTION [WL-C, WE-C]
dcfO 1164272OW02
Note
• The rollover valve cannot be disassembled and inspected as it is integrated in the fuel tank. , .
1. Perform the fuel tank inspection. (See 01-148-8 FUEL TANK INSPECTION [WL-C, WE-C].)
01-168-8
CHARGING SYSTEM
01-17 CHARGING SYSTEM

CHARGING SYSTEM GENERATOR
LOCATION INDEX . ................ 01-17-1 REMOVAUINSTALLATION ......... . 01-17-4
BATTERY REMOVAUINSTALLATION .. 01-17-2 GENERATOR INSPECTION . ......... . 01-17-5
BATTERY INSPECTION ............. 01-17-2 GENERATOR
BATTERY RECHARGING . ........... 01-17-4 DISASSEMBLY/ASSEMBLY .. ...... . 01-17-8
CHARGING SYSTEM LOCATION INDEX
DBGl17ZWB004
Battery 2 Generator
(See 01-17-2 BATTERY REMOVAU (See 01-17-4 GENERATOR REMOVAU
INSTALLATION.) INSTALLATION.)
(See 01-17-2 BATTERY INSPECTION.) (See 01-17-5 GENERATOR INSPECTION.)
(See 01-17-4 BATTERY RECHARGING.) (See 01-17-8 GENERATOR DISASSEMBLY/
ASSEMBLY.)
01-17-1
CHARGING SYSTEM
BATTERY REMOVAL/INSTALLATION
dcf01171852OW01
1 Negative battery cable
2 Positive battery cable
(See 01-17-2 Positive Battery Cable Installation
Note.)
3 Battery clamp
4 Battery
5 Battery tray
DBG117ZWB002
Positive Battery Cable Installation Note
Note
• Secure the positive battery cable to the battery clamp with the band.
BATTERY INSPECTION
dcf01171852OW02
Warning
• Since battery acid is toxic, be careful when handling the battery.
• Since battery acid is highly corrosive, be careful not to allow it to contact clothing or the vehicle.
• In case battery acid contacts skin, eyes, or clothing, flush it immediately with running water.
EspeCially if the acid gets in the eyes, flush with water for more than 15 min and get prompt
medical attention. '
Electrolyte specific gravity

1. Measure the electrolyte specific gravity using a hydrometer.
• If it is less than the specification, recharge the battery. (See 01-17-4 BATTERY RECHARGING.)
Battery electrolyte specific gravity [20°C {68 OF}]

1.22-1.29
Battery voltage
1. Inspect the battery as follows:
Step Inspection Action
1 Measure the battery 12.4 Vor Go to Step
positive voltage. more 3.
Less Go to the
than next step.
12.4 V
2 Quick charge for 30 12.4 Vor Go to the
min and recheck more next step.
voltage. Less Replace the
than battery.
12.4 V
01-17-2
CHARGING SYSTEM

3 Using the battery load Yes Normal
tester, apply load No Replace the
current (see battery battery.
load test current) and
record battery voltage
after 15 s. Is voltage
more than
specification?

65031 R (56): 165 A
75026R (52): 195 A
75026L (52): 195 A
95031 R (64): 250 A
Standard specification
Battery temp. (Oe eF}) Minimum voltage (V)
4 {39} 9.3
10 {50} 9.4
16 {61} 9.5
21 {70} 9.6
Back-up current
1. Verify that the engine switch is off (key has been removed) and that all doors are closed.
3. Connect the tester between the negative battery terminal and negative battery cable, leave the battery
undisturbed for 15 min., and then measure the back-up current.
• If not within the specification, measure the back-up current while removing the fuses one by one from the
inside of the main fuse block and the inside of the fuse block.
Note
• If the battery is not left undisturbed for 15 min., the tester will indicate a high value (approx. 200 mA).
• If the key or any electrical accessory is operated within approx. 15 min. after the tester is connected, the
battery must be left undisturbed for approx. 15 min. from that point.
Caution
• Operating electrical loads while the back-up current is being measured can damage the tester.
Note
• For the vehicles with the immobilizer system, periodically shifts synchronization of the security light
flashing. Therefore, 25 rnA (0.1 s) current is supplied when the security light is illuminated, and 5 mA (2 s)
current is supplied when the security light is not illuminated. In addition, the measuring instrument, which
shows the average value, indicates around 10 rnA.

4. Inspect and repair wiring harnesses and connectors of the fuse where the current has decreased.
01-17-3
CHARGING SYSTEM
BATTERY RECHARGING
dcf01171852Ow03
Warning
• Keep all flames away from the battery, otherwise evaporated gas from the battery fluid may catch
fire, and cause serious injury.
• Remove the battery filler caps when recharging to prevent battery deformation or damage.
Caution
• Do not quick charge for more than 30 min. It will damage the battery.
1. Remove the battery and then place it in a pan of

water.
2. Remove the battery filler caps.
3. Connect a battery charger to the battery and
adjust the charging current as follows.
BATTERY
Battery slow charge current CHARGER
65031 R (56): 4.0-5.0 A
75026R (52): 5.0-6.0 A
75026L (52): 5.0-6.0 A
95031 R (64): 6.5-8.0 A
Battery quick charge current [30 min]

650~1 R (56): 30 A
75026R (52): 35 A CHU0117W004
75026L (52): 35 A
95031 R (64): 40 A
4. After the battery is recharged, verify that the
voltage is within the specification and remains at
the same value for 1 h or more after the recharging was completed.
• If not within the specification, replace the battery.
Standard voltage
12.4 V or more
GENERATOR REMOVAUINSTALLATION
dcf01171830Ow01
Warning
• When the battery cables are connected, touching the vehicle body with generator terminal B will
generate sparks. This can cause personal injury, fire, and damage to the electrical components.
Always disconnect the battery negative cable before performing the following operation.

4. Inspect the drive belt deflection/tension. (See 01-
10A-3 DRIVE BELT INSPECTION [WL-3].) (See
01-10B-3 DRIVE BELT INSPECTION [WL-C,
WE-C].)
1 B terminal cable
2 Generator connector
3 Drive belt
4 Generator
(See 01-17-5 Generator Installation Note.)
N?m {kgf?m, ft?lb
01-17-4 DBG117ZWB003
CHARGING SYSTEM
Generator Installation Note
1. Tighten locknut A by hand.
2. Tighten mounting nut B.
Tightening torque:
12-25 N·m {123-254 kgf.cm, 107-221 in·lbf}
3. Adjust the drive belt deflection or tension by turning adjusting bolt C. (See 01-1 OA-3 DRIVE BELT
INSPECTION [WL-3].) (See 01-10B-3 DRIVE BELT INSPECTION [WL-C, WE-C].)
4. Tighten mounting nut B and locknut A.
GENERATOR INSPECTION
dcf011718300w02
Generator Warning Light

1. Verify that the battery is fully charged.
• Charge if necessary.
2. Verify that the drive belt deflection/tension is within the specification. (See 01-10A-3 DRIVE BELT
3. Turn the engine switch on and verify that the generator warning light illuminates.
• If not as specified, inspect the generator warning light, and wiring harnesses between the battery and the
generator warning light.
4. Verify that the generator warning light goes out after the engine is started.
• If not as specified, inspect the generator.
Generator
Voltage
2. Verify that the drive belt deflection/tension is within the specification. (See 01-1 OA-3 DRIVE BELT
4. Turn the engine switch to start the engine and verify that the generator rotates smoothly without any noise while
the engine is running.
5. Measure the voltage at each terminal using a
tester. GENERATOR
• If not as specified, repair or replace the WIRING HARNESS-SIDE CONNECTOR
generator if necessary.
Generator standard voltage [Engine switch

ON]
Terminal B: B+
Terminal L: Approx. 1 V
Terminal S: B+
Generator standard voltage [Idle, 20°C {S8

DBG117ZWB850
OF}]
Terminal B: 14.1-14.7 V
Terminal L: 13.0-14.0 V
01-17-5
CHARGING SYSTEM
Current
Note
• Since the charging current decreases rapidly after starting the engine, perform the following procedure
quickly, and read the maximum current value.

2. Verify that the drive belt deflection/tension is within the specification. (See 01-1 OA-3 DRIVE BELT
INSPECTION [WL-3].) (See 01-1 OB-3 DRIVE BELT INSPECTION [WL-C, WE-C].)
4. Connect a tester, which can read 120 A or more, between generator terminal B and the wiring harness.
6. Start the engine and increase the engine speed to 2,000-2,500 rpm.
7. Turn the following electrical loads on and verify that the current reading increases.
(1) Headlights
(2) Blower motor
(3) Rear window defroster
• If generator terminal B current does not increase, repair or replace the generator if necessary.
Note
• Current required for generating power varies with the electrical loads applied.
13.5 V, Engine hot
1,000 0-55 A
2,000 0-70 A
Generator Inner Parts

Rotor
1. Measure the resistance between the slip rings
using a tester.
• If not as specified, replace the rotor.
Generator rotor resistance (between slip

rings) [20°C {68 OF}]
2.3-2.7 ohms
CHU0117W005
2. Verify that there is no continuity between the Slip

ring and core using a tester.
• If there is continuity, replace the rotor.
3. Inspect the slip ring surface condition.
• If the slip ring surface is rough, use a lathe or
fine sandpaper to repair it.
CHU0117W006
01-17-6
CHARGING SYSTEM
Stator coil
1. Inspect for continuity between the stator coil leads
using a tester.
• If there is no continuity, replace the stator.
2. Verify that there is no continuity between the

stator coil leads and the core using a tester.
• If there is continuity, replace the stator coil.
CHU0117W008
Brush
1. Inspect brushes for wear.
• If any brush is worn almost to or beyond the
fE
limit, replace all of the brushes.

Standard: 18.5 mm {0.73 in} t
S"[ANDARD
A
!
CHU0117W009
Brush spring
1. Measure the force of the brush spring using a spring pressure gauge.
2. Read the spring pressure gauge at the brush tip ,-----------;-------;----------,
projection of 2 mm {0.079 in}.
• Replace the brush spring if necessary.

Standard: 4.8-6.0 N {0.49-0.61 kgf, 1.08-
1.34Ibf}
Minimum: 2.16 N {0.22 kgf, 0.49 Ibf}
01-17-7
CHARGING SYSTEM
Rectifier
1. Inspect for continuity of the diodes using a tester.
• If not as specified, replace the rectifier.
Specification
Tester P1
Negative Positive
Continuity •
P2
E Yes
B
P1, P2, P3
No
•
P3
P1, P2, P3
E No •
B Yes
DPE117BW1003
P1
DPE117BW1004
Bearing
1. Inspect for abnormal noise, looseness, and
sticking.
• Replace the bearing if necessary.
CHU0117W015
GENERATOR DISASSEMBLY/ASSEMBLY
dcf01171830Ow03
Caution
• Melt the solder quickly, otherwise the diodes (rectifier) and regulator will be damaged by excessive
heat.

01-17-8
CHARGING SYSTEM
127-18.6
{13Q-189,113-164}
3.4-5.4
{3!C-55~
2.9-4.9~
{30-49,
26-43}
~
r~
98-137 N·m
{10.Q-13.9 kgf·m, 2.9-4.9
{30-49,
73-101 ft·lbf}
26-43}
{30-49,
26-43}
5
N·m {kgf·cm, in·lbf}
DBG117ZWB001
Front cover 5 . Stator coil

2 Pulley 6 Rectifier
3 Rotor 7 Brush holder
4 Bearing 8 Rear bracket
01-17-9
STARTING SYSTEM
01-19 STARTING SYSTEM

STARTING SYSTEM STARTER REMOVAL/
LOCATION INDEX ................. 01-19-1 INSTALLATION [WL-C, WE-C] ...... . 01-19-2
STARTER STARTER INSPECTION . ............ . 01-19-3
REMOVAL/INSTALLATION [WL-3] .... 01-19-2 STARTER
DISASSEMBLy/ASSEMBLy ......... 01-19-8
STARTING SYSTEM LOCATION INDEX
DBG119ZWB003
Starter
(See 01-19-2 STARTER REMOVAUINSTALLATION
[WL-3].)
(See 01-19-2 STARTER REMOVAUINSTALLATION
[WL-C, WE-C].)
(See 01-19-3 STARTER INSPECTION.)
(See 01-19-8 STARTER DISASSEMBLY/
ASSEMBLY.)
01-19-1
STARTING SYSTEM
STARTER REMOVAUINSTALLATION [WL-3]
dcf01191840Ow01
Warning
• When the battery cables are connected, touching the vehicle body with starter terminal B will i .'
Always disconnect the negative battery cable before performing the following operation.
1. Remove the battery. (See 01-17-2 BATTERY REMOVAUINSTALLATION.)

38-51 {3.9-5.2,29-37}
1 Terminal B cable
2 Terminal S connector
3 Starter
(See 01-19-2 Starter Installation Note.)
3
DBG119ZWB002
Starter Installation Note

1. Temporarily tighten the installation bolts.
2. Tighten the installation bolts.
STARTER REMOVAUINSTALLATION [WL-C, WE-C]

dcf01191840Ow02
Warning
• When the battery cables are connected, touching the vehicle body with starter terminal B will
Always disconnect the negative battery cable before performing the following operation.

2. Remove the battery and battery tray. (See 01-17-2 BATTERY REMOVAUINSTALLATION.)
3. Set the fuel filter component slightly out of the way. (See 01-14B-9 FUEL FILTER REMOVAUINSTALLATION
[WL-C, WE-C].)
4. Set the bracket that secure the intake shutter solenoid valve out of the way.
38-51 {3.9-5.2, 29-37} 9.8-11.7 N·m
1 Terminal B cable {100_119 kgf.cm,
~
J~~71b'
2 Terminal S connector
3 Starter
(See 01-19-3 Starter Installation Note.)
3
DBG119ZWB002
01-19-2
STARTING SYSTEM
Starter Installation Note
1. Temporarily tighten the installation bolts.
2. Tighten the installation bolts.
STARTER INSPECTION
On-vehicle Inspection
2. The starter is normal if it rotates smoothly and without any noise when the engine is cranked.
• If the starter does not operate, inspect the following:
- Remove the starter, and inspect the starter unit.
- Inspect the related wiring harnesses and the engine switch.
No-load test
2. Connect the starter, battery, and a tester as
ENGINE SWITCH TESTER
3. Operate the starter and verify that it rotates
smoothly. r---~~----~~A
• If the starter does not rotate smoothly, inspect

the starter unit. TESTER T
4. Measure the voltage and current while the starter V : BATTERY
is operating. ..L

starter.
Starter no load test voltage

DPEl19BW1003
11 V
Starter no load test current

130 A or less
Magnetic Switch Operation Inspection

Pull-out test
Note
• Depending on the battery charge condition, the starter motor pinion may rotate while in a protracted state.
This is due to current flowing to the starter motor through the pull-in coil to turn the starter motor, and does
not indicate an abnormality.
1. Verify that the starter motor pinion is protracted

while battery positive voltage is connected to
terminal S and the starter body is grounded.
• If flot pulled out, repair or replace the starter.
CHUOl19W023
Return test
1. Disconnect the motor wire from terminal M.
01-19-3
STARTING SYSTEM
2. Connect battery positive voltage to terminal M
and ground the starter body.
3. Pull out the drive pinion with a screwdriver. Verify
that it returns to its original position when
released.
• If it does not return, repair or replace the
starter.
CHU0119W022
Pinion Gap Inspection

1. Pull out the drive pinion with the battery positive
voltage connected to terminal S and the starter
body grounded.
Caution
• Applying power for more than 10 scan
damage the starter. Do not apply power
for more than 10 s.
CHU0119W023
2. Measure the pinion gap while the drive pinion is

pulled.
• If not as specified, adjust with an adjustment
washer (between drive housing front cover
and magnetic switch).
Starter pinion gap

o mm {O in}
PINION GAP
"'
DPE119BW1005
Starter Inner Parts Inspection

Armature
1. Verify that there is no conductivity between the
commutator and the core at each segment using
a tester.
• If there is conductivity, replace the armature.
01-19-4
STARTING SYSTEM
2. Verify that there is no conductivity between the
commutator and the shaft using a tester.
• If there is conductivity, replace the armature.
3. Place the armature on V-blocks, and measure the

runout using a dial indicator.
Starter armature runout

0.1 mm {0.039 in} max.
CHU0119W018
4. Measure the commutator diameter.

• If not within the minimum specification,
replace the armature.

CHU0119W019
5. Measure the segment groove depth of the

commutator.
undercut the grooves to the standard depth.

CHU0119W020
01-19-5
STARTING SYSTEM
Magnetic switch
1. Inspect for conductivity between terminals Sand
M using a tester.
• If there is no conductivity, replace the
magnetic switch.
2. Inspect for conductivity between terminal Sand

the body using a tester.
• If there is no conductivity, replace the
magnetic switch.
CHU0119W008
3. Verify that there is no conductivity between

TERMINAL M
terminals M and B using a tester.
• If there is conductivity, replace the magnetic
switch.
TERMINAL B
CHU0119W009
Brush and brush holder

1. Verify that there is no conductivity between each
insulated brush and plate using a tester.
• If there is conductivity, replace the brush
holder.
CHU0119W012
01-19-6
STARTING SYSTEM
2. Measure the brush length.
• If any brush is worn almost to or beyond the
minimum specification, replace all the
brushes. MINIMUM
BRUSH
LENGTH
CONTACT FACE WITH COMMUTATOR
3. Measure the brush spring force using a spring

balance.
replace the brush spring.

Standard: 26.7-36.1 N {2.73-3.68 kgf,
6.01-8.11 Ibf}
Minimum: 14.7 N {1.5 kgf, 3.3Ibf}
CHU0119W014
01-19-7
STARTING SYSTEM
STARTER DISASSEMBLY/ASSEMBLY
dcf01191840Ow04

6.9-12.7
{71-129,
62-112}
DBG119ZWB001
1 Magnetic switch 9 Drive pinion

2 Rear housing 10 Internal gear
3 Brush and brush holder 11 Gear shaft
4 Armature
5 Yoke
6 Planetary gear
7 Front cover
8 Lever
01-19-8
01-408 CONTROL SYSTEM [WL-C, WE-C]

CONTROL SYSTEM IDLE SWITCH INSPECTION
LOCATION INDEX [WL-C, WE-C] ..•. 01-408-2 [WL-C, WE-C] .............•..•.•• 01-408-30
CONTROL SYSTEM FUEL TEMPERATURE SENSOR
WIRING DIAGRAM [WL-C, WE-C] .... 01-408-4 INSPECTION [WL-C, WE-C] ......... 01-408-32
CONTROL SYSTEM FUEL PRESSURE SENSOR
DIAGRAM [WL-C, WE-C] •.......•.. 01-408-8 INSPECTION [WL-C, WE-C] ..•.••... 01-408-33
PCM REMOVAL/INSTALLATION ENGINE COOLANT TEMPERATURE
[WL-C, WE-C] . • . • . . . • . . • . . . . . . . . . 01-408-9 (ECT) SENSOR REMOVAL/
PCM INSPECTION [WL-C, WE-C] ..•.. 01-408-10 INSTALLATION [WL-C, WE-C] ....... 01-408-34
PCM CONFIGURATION ENGINE COOLANT TEMPERATURE
[WL-C, WE-C] .•...•••.•........•• 01-408-20 (ECT) SENSOR INSPECTION
FUEL INJECTOR CODE PROGRAM [WL-C, WE-C] ....•........•..•.•• 01-408-35
[WL-C, WE-C] .•...•.•.••.......•• 01-408-21 CAMSHAFT POSITION (CMP)
PCM DATA RESET [WL-C, WE-C] ..... 01-408-22 SENSOR REMOVAL/
MASS AIR FLOW (MAF) SENSOR INSTALLATION [WL-C, WE-C] .••.•.. 01-408-36
DATA RESET [WL-C, WE-C] ••.•.... 01-408-22 CAMSHAFT POSITION (CMP) SENSOR
MAIN RELAY INSPECTION INSPECTION [WL-C, WE-C] ..•..•.•• 01-408-37
[WL-C, WE-C] ...•....••.•..•..... 01-408-23 CRANKSHAFT POSITION (CKP)
MASS AIR FLOW (MAF) SENSOR! SENSOR REMOVAL/INSTALLATION
INTAKE AIR TEMPERATURE (IAT) [WL-C, WE-C] ..•....•.•..••...•.•. 01-408-38
SENSOR NO.2 INSPECTION CRANKSHAFT POSITION (CKP)
[WL-C, WE-C] . . . . . . . . . . . . . • • . • . . . 01-408-23 SENSOR INSPECTION
INTAKE AIR TEMPERATURE (IAT) [WL-C, WE-C] .......•..........•.. 01-408-39
SENSOR NO.1 INSPECTION EGR VALVE POSITION SENSOR
[WL-C, WE-C] .................... 01-408-26 INSPECTION [WL-C, WE-C] ..•.•...• 01-408-40
800ST SENSOR INSPECTION CLUTCH PEDAL POSITION (CPP)
[WL-C, WE-C] .....•.•..•.......•• 01-408-27 SWITCH INSPECTION
ACCELERATOR PEDAL POSITION [WL-C, WE-C] •.•....•.•.••...•... 01-408-42
(APP) SENSOR INSPECTION NEUTRAL SWITCH INSPECTION
[WL-C, WE-C]. . . . . • • . . • • . . . . . . . . . 01-408-28 [WL-C, WE-C] .••.•.............•• 01-408-43
01-408-1
CONTROL SYSTEM LOCATION INDEX [WL-C, WE-C]
dcf014000000w05
DBG140BWB107
1 PCM (8uilt into 8ARO sensor) 4 ECT sensor

(See 01-408-9 PCM REMOVAUINSTALLATION (See 01-408-34 ENGINE COOLANT
[WL-C, WE-C].) TEMPERATURE (ECT) SENSOR REMOVAU
(See 01-408-10 PCM INSPECTION [WL-C, WE-C].) INSTALLATION [WL-C, WE-C].)
2 MAF sensor/IAT sensor No.2 (See 01-408-35 ENGINE COOLANT
(See 01-408-23 MASS AIR FLOW (MAF) SENSOR/ TEMPERATURE (ECT) SENSOR INSPECTION
INTAKE AIR TEMPERATURE (IAT) SENSOR NO.2 [WL-C, WE-C].)
INSPECTION [WL-C, WE-C].) 5 CKP sensor
3 800st sensor/IAT sensor No.1 (See 01-408-38 CRANKSHAFT POSITION (CKP)
(See 01-408-27 800ST SENSOR INSPECTION SENSOR REMOVAUINSTALLATION [WL-C, WE-
[WL-C, WE-C].) C).)
(See 01-408-26 INTAKE AIR TEMPERATURE (IAT) (See 01-408-39 CRANKSHAFT POSITION (CKP)
SENSOR NO.1 INSPECTION [WL-C, WE-C].) SENSOR INSPECTION [WL-C, WE-C].) \ -
01-408-2
6 CMP sensor 10 CPP sensor

(See 01-408-36 CAMSHAFT POSITION (CMP) (See 01-408-42 CLUTCH PEDAL POSITION (CPP)
SENSOR REMOVAUINSTALLATION [WL-C, WE- SWITCH INSPECTION [WL-C, WE-C).)
C).) 11 Idle switch
(See 01-408-37 CAMSHAFT POSITION (CMP) (See 01-408-30 IDLE SWITCH INSPECTION [WL-
SENSOR INSPECTION [WL-C, WE-C).) C, WE-C].)
7 Fuel pressure sensor 12 main relay
(See 01-408-33 FUEL PRESSURE SENSOR (See 01-408-23 MAIN RELAY INSPECTION [WL-C,
INSPECTION [WL-C, WE-C].) WE-C].)
8 EGR valve position sensor 13 APP sensor
(See 01-408-40 EGR VALVE POSITION SENSOR (See 01-408-28 ACCELERATOR PEDAL
INSPECTION [WL-C, WE-C).) POSITION (APP) SENSOR INSPECTION [WL-C,
9 Fuel temperature sensor WE-C].)
(See 01-408-32 FUEL TEMPERATURE SENSOR 14 Neutral switch
INSPECTION [WL-C, WE-C].) (See 01-408-43 NEUTRAL SWITCH INSPECTION
[WL-C, WE-C].)
01-408-3
CONTROL SYSTEM WIRING DIAGRAM [WL-C, WE-C]
dcf014000000w06
.J:-+----{E
DLC
r---------r~-----++-~------------+_----------------~IG-
FEN
KLN
TEN
F
DLC-2
KLN
'-------I TEN
PCM
(BUILT INTO
GLOW INDICATOR
BARO SENSOR)
LIGHT
VEHICLE
SPEED SIGNAL
FUEL
INJECTOR
FUEL
INJECTOR
NO.3
FUEL
INJECTOR
NO.2
FUEL
INJECTOR
NO.1
DBG 102BWBY01
01-408-4
RFWLOCK
SOLENOID
APP il---;-+...r VALVE
SENSOR
RFWFREE
SOLENOID
VALVE
FUEL PRESSURE
SENSOR
BOOST
SENSOR
CMPSENSOR
FUEL
CKPSENSOR
TEMPERATURE
SENSOR
EGRVALVE
POSITION
SENSOR PCM
Il--t--o 0--+--+-.... GLOW

PLUG
BLOWER '-------'
RELAY
MOTOR
.-----------------------------------------
,,, REFRIGERANT
,, PRESSURE
,, - ---------------------------,
,, SWITCH (LOW) VARIABLE SWIRL :
,, ~r--~~ ~-+~~ CONTROL ,
, SOLENOID VALVE :
,,, AlC
,, COMPRESSOR
,,
,
,,, AlC RELAY
,,
:AlC
:SWITCH
: THERMO SWITCH
,,
'- - - - - - - - - - - - - - - • WITH AlC· - - - - - - - - - - - - - - -
DBG102BWBY02
01-408-5
; ,
-I:-+----{E
DLC
IG-
FEN
KLN
TEN
F
DLC-2
L...----1KLN
L-----1TEN
PCM
(BUILT INTO
GLOW INDICATOR
LIGHT ~-+-------1r----------{
BARO SENSOR)
VEHICLE
SPEED SIGNAL
FUEL
INJECTOR
FUEL
INJECTOR
NO.3
FUEL
INJECTOR
NO.2
FUEL
INJECTOR
IAT NO.1
SENSOR
NO.2
DBG102BWBY03
01-408-6
C
- - - - - - - - - - - - - - - -WITH RFW -.
RFWLOCK
SOLENOID
APP :}---+--t:""J VALVE
SENSOR
FUEL PRESSURE
SENSOR
BOOST
SENSOR
CMP SENSOR
ECT
SENSOR LJ.!-I----{
FUEL CKPSENSOR
TEMPERATURE
SENSOR
EGRVALVE
POSITION
SENSOR PCM
F
n---+--o 0--+--1-... GLOW
PLUG
BLOWER '-------'
RELAY
MOTOR
------- ---------------------------------
REFRIGERANT : ·
PRESSURE : - ---------------------------.
SWITCH (LOW) ,-----,: VARIABLE SWIRL:
~ O--~.~~ CONTROL :
SOLENOID VALVE :
AlC
COMPRESSOR
'-------': ··
AlC RELAY'
··
:AlC
:SWITCH
·····
: THERMO SWITCH
··'- - - - - - - - - - - - - - - • WITH AlC· - - - - - - - - - - - - - - -
DBG102BWBY02
01-408-7
CONTROL SYSTEM DIAGRAM [WL-C, WE-C]
dcf014000000w07
....I
~I I I Z <t:
u:lg ()
f-
()
f-
w
e Z
QJ
a:3'; ~ ~ C\J ii5
ZOO 00 00
0....I 0
~ ~ <;!
~
LU
:2 - a: 0 LU 00
a. ::>
I QJ f- I I
I Z ::> I I 00 [!l
I w W I I LU
Z
I Z I
I
I
I
....I
() <t:
I I
I I ()
-*:TOPCM
I I
I I I
-----.. : FUEL FLOW
I
I
TACHOMETER ---I t_~::--,
I
:
I
I ,.
I
I I
I
,___ I
I
I
I
I
W
>I
r---- .. I
GLOW INDICATOR LIGHT -j L_
1___ -
I
,-J.....!...I...!'--!......L...~ I
_____ 1
---- CPP SWITCH

---- AlC RELAY
EGRVALVE
APP IDLE
SENS~CH
ACCELERATOR
PEDAL
VARIABLE SWIRL CONTROL VALVE
TO VACUUM RESERVER TANK

FOR BRAKE SYSTEM
DBG140BTB002
01-408-8
PCM REMOVAUINSTALLATION [WL-C, WE-C]
dcf014018880w09
Note
• If the PCM is replaced, always perform each adjustment procedure using the following steps.
1. Disconnect the battery negative cable.

2. Remove the passenger's side front side trim.
·1 PCM Connector
2 PCM
Bracket 7.8-10.8 N·m
3
7.8-10.8 N·m
{80-110 kgf.cm,
69.0-95.5 in·lbf}
DBG140BWB850
01-408-9
PCM INSPECTION [WL-C, WE-C]
dcf014018880w10
Without Using the current diagnostic tool
Note
• The PCM terminal voltage can vary with the conditions when measuring and changes due to aged
deterioration on the vehicle, causing false diagnosis. Therefore determine comprehensively where the
malfunction occurs among the input systems, output systems, and the PCM.
PCM
219218217216215214213212211210209208207
232 231 230 229 228 227 226 225 224 223 222 221 220
245 244 243 242 241 240 239 238 237 236 235 234 233
258 257 256 255 254 253 252251 250 249 248 247246
DBG140BWB001
Terminal voltage table (Reference)

Voltage
Terminal Signal Connected to Test condition Inspection item
(V)
Inspect using the wave profile. • Inspect related
101 Fuel injector (#3) Fuel injector No.3 (See 01-40B-16 Inspection Using An wiring harness
Oscilloscope (Reference).) • Fuel injector No.3
103 - - - - -
104 - - - - -
105 - - - - -
• Inspect related
EGR valve position wiring harness
106 Constant voltage Engine switch ON Approx.5
sensor • EGR valve position
sensor
107 - - - - -
108 - - - - -
• Inspect related
Fuel pressure wiring harness
sensor • Fuel pressure
sensor
• Inspect related
EGR valve position wiring harness
110 Ground Under any condition Below 1.0
sensor • EGR valve position
sensor
• Inspect related
BoosVIAT sensor wiring harness
No.1 • BoosVIAT sensor
No.1
112 - - - - -
113 - - - - -
• Inspect related
114 Ground CMP sensor Under any condition Below 1.0 wiring harness
• CMP sensor
Fuel
Approx.
temperature
2.5 • Inspect related
Fuel temperature Engine switch 40°C {1 04 OF} wiring harness
115 Fuel temp
sensor ON Fuel
Approx.
• Fuel temperature
temperature sensor
2.3
45°C {113 OF}
01-408-10
Voltage
(V)
Engine switch ON Below 1.0 • Inspect related
116 EGR position EGR valve wiring harness
EGR valve opening angle 40% Approx.2
• EGR valve
117 - - - - -
118 - - - - -
119 - - - - -
120 - - - - -
121 - - - - -
122 - - - - -
123 - - - - -
124 - - - - -
127 - - - - -
AlC operating Below 1.0 • Inspect related
128 AlC AlC relay wiring harness
AlC not operating B+
• AlC relay
• Inspect related
129 Constant voltage CMP sensor Engine switch ON Approx.5 wiring harness
• CMP sensor
130 - - - - -
131 - - - - -
132 - - - - -
• Inspect related
BoostilAT sensor wiring harness
No.1 • BoostilAT sensor
No.1
134 - - - - -
Transfer shift lever neutral
Below 1.0 • Inspect related
Transfer neutral position wiring harness
135 neutral switch
switch
Except above B+
• Transfer neutral
switch
136 - - - - -
Transfer shift lever 2H position B+ • Inspect related
137 4x4 indicator switch 4x4 indicator switch wiring harness
Except above Below 1.0
• 4x4 indicator switch
138 - - - - -
139 - - - - -
Idle
Approx. • Inspect related
Fuel pressure 1.2 wiring harness
140 Fuel pressure
sensor
Engine speed is 2,800 rpm
Approx. • Fuel pressure
2.5 . sensor
IAT 30°C Approx. • Inspect related
BoostilAT sensor Engine switch {86 OF} 1.9 wiring harness
141 IAT
No.1 ON IAT 50°C Approx. • BoostilAT sensor
{122 OF} 1.2 No.1
142 - - - - -
143 - - - - -
144 - - - - -
145 - - - - -
146 - - - - -
147 - - - - -
148 - - - - -
01-408-11
Voltage
(V)
151 - - - - -
Engine switch ON B+
B+ • Inspect related
Intake shutter Intake shutter wiring harness
152 (WL-C)
solenoid valve (half) solenoid valve (half) Idle
Below 1.0
• Intake shutter
solenoid valve (half)
(WE-C)
153 - - - - -
• Inspect related
MAF/IAT sensor wiring harness
No.2 • MAF/IAT sensor
No.2
• Inspect related
Intake shutter Intake shutter wiring harness
155 Engine switch ON B+
solenoid valve (full) solenoid valve (full) • Intake shutter
solenoid valve (full)
• Inspect related
156 Ground ECT sensor Under any condition Below 1.0 wiring harness
• ECT sensor
157 - - - -"".-
158 - - - - -
159 - - - - -
160 CMP CMP sensor (See 01-40B-16 Inspection Using An wiring harness
Oscilloscope (Reference).) • CMP sensor
Engine switch On B+ • Inspect related
161 Idle Idle switch wiring harness
Idle Below 1.0
• Idle switch
162 - - - - -
163 - - - - -
164 - - - - -
165 - - - - -
166 - - - - -
ECT 30°C Approx.
{86 OF} 2.6
ECT 40°C Approx.
Engine switch {104 OF} 2.1 • Inspect related
167 ECT ECT sensor wiring harness
ON ECT 50°C Approx.
{122 OF} 1.8
• ECT sensor
ECT 60°C Approx.

{140 OF} 1.4
168 - - - - -
• Inspect related
No.2 • MAF/IAT sensor
No.2
• Inspect related
Fuel temperature wiring harness
sensor • Fuel temperature
sensor
171 CAN (L) -

Because this terminal is for CAN, no valid • Inspect related
determination of terminal voltage is possible wiring harness
172 - - - - -
Oscilloscope (Reference).) • Fuel injector NO.3
01-408-12
Voltage
(V)
175 - - - - -
Engine switch ON B+ • Inspect related
176 EGR solenoid valve EGR solenoid valve Approx. wiring harness
Idle
3.5 • EGR solenoid valve
Engine switch ON B+ • Inspect related
EGR control EGR control wiring harness
177
solenoid valve solenoid valve Idle Below 1.0 • EGR control
solenoid valve
178 VBC solenoid valve VBC solenoid valve (See 01-40B-16 Inspection Using An wiring harness
Oscilloscope (Reference).) • VBC solenoid valve
179 Fuel Metering Valve Fuel Metering Valve (See 01-40B-16 Inspection Using An wiring harness
Oscilloscope (Reference).) • Fuel Metering Valve
180 - - - - -
• Inspect related
Variable swirl Variable swirl wiring harness
Approx.
181 control solenoid control solenoid Engine switch ON
3.3 • Variable swirl
valve valve control solenoid
valve
13 s from when engine switch is
turned to ON position with ECT at
20°C {68 OF} or less
182 Glow Glow plug relay wiring harness
Idle (2m or more after engine is
Below 1.0
• Glow plug relay
started)
183 - - - - -
184 Vehicle speed VSS (See 01-40B-16 Inspection Using An wiring harness
Oscilloscope (Reference).) • VSS
RFW"LOCK" Below 1.0 • Inspect related
185 RFW switch RFW Switch wiring harness
RFW"FREE" B+
• RFW switch
186 - - - - -
187 - - - - -
IAT 30°C
{86 OF}
Approx.
1.9
• Inspect related
MAF/IAT sensor Engine switch wiring harness
188 IAT
No.2 ON IAT 50°C Approx. • MAF/IAT sensor
{122 OF} 1.2 No.2
BoosVIAT sensor Approx. • Inspect related

189 MAP Engine switch ON wiring harness
No.1 1.6
• Boost sensor
190 MAF Approx.
No.2 Idle
1.8
• MAF/IAT sensor
No.2
• Inspect related
Fuel pressure wiring harness
sensor • Fuel pressure
sensor
192 CKP CKP sensor (See 01-40B-16 Inspection Using An wiring harness
Oscilloscope (Reference).) • CKP sensor
193 CKP CKP sensor (See 01-40B-16 Inspection Using An wiring harness
Oscilloscope (Reference).) • CKP sensor
• Inspect related
194 Ground CKP sensor Under any condition . Below 1.0 wiring harness
• CKP sensor
01-408-13
Voltage
Terminal Signal Connected to . Test condition Inspection item
(V)
195 CAN (H) - Because this terminal is for CAN, no valid • Inspect related
determination of terminal wiring harness
196 - - - - -
Main relay ON B+ • Inspect related
201 B+ Main relay wiring harness
Main relay OFF Below 1.0
• Main relay
202 Ground Body ground Under any condition Below 1.0 • Inspect related
wiring harness
• Main relay
wiring harness
• Main relay
wiring harness
207 - - - - -
208 - - - - -
Accelerator pedal released Below 1.0 • Inspect related
209 APP APP sensor Approx. wiring harness
Accelerator pedal depressed
3.6 • APP sensor
210 - - - - -
211 - - - - -
• Inspect related
212 Ground APP sensor Under any condition Below 1.0 wiring harness
• APP sensor
• Inspect related
213 Constant voltage APP sensor Engine switch ON Approx.5 wiring harness
• APP sensor
214 - - - - -
215 - - - - -
216 - - - - -
217 - - - - -
218 - - - - -
219 Main relay control Main relay wiring harness
Engine switch OFF B+
• Main relay
220 - - - - -
221 - - - - -
Accelerator pedal released Below 1.0 • Inspect related
222 APP APP sensor Approx. wiring harness
Accelerator pedal depressed
3.6 • APP sensor
223 - - - - -
224 - - - - -
Engine switch is ON and Start
225 IG 1 Engine switch position
wiring harness
Engine switch is other position Below 1.0
Open terminal
Data link connector B+
226
Diagnostic test
(DLC) (Terminal
Engine switch TEN • Inspect related
mode ON Short terminal wiring harness
TEN) Below 1.0
TEN
01-408-14
Voltage
(V)
For less than
approx.13
seconds after B+
turning engine
switch ON.
Over approx. 13
seconds after
Below 1.0
ECTis below turning engine
60°C {140 OF} switch dN.
For less than 2
minutes starting B+
engine.
Over 2 minutes • Inspect related
227 Glow system Glow relay after starting Below 1.0 wiring harness
engine. • Glow relay
While cranking B+
For less than
approx.4
seconds after B+
turning engine
ECT is above switch ON.
60°C {140 OF} Over approx. 4
seconds after
Below 1.0
turning engine
switch ON.
While cranking Below 1.0
Clutch pedal released B+ • Inspect related
228 Clutch CPP switch wiring harness
Clutch pedal depressed Below 1.0
• CPP switch
229 - - - - -
Coil
230 (Immobilizer
Immobilizer-related No valid determination of terminal voltage is • Inspect related
information possible wiring harness
system)
Data link connector No DTC output B+
231 DTC output (DLC) (Terminal • Inspect related
DTC output Below 1.0 wiring harness
TEN)
4x4 indicator light OFF Below 1.0 • Inspect related
wiring harness
232 4x4 indicator light 4x4 indicator light
4x4 indicator light ON B+ • Instrument cluster
(4x4 indicator light)
Engine switch OFF
Engine switch is ON and within Below 1.0 • Inspect related
233 Glow indicator light Glow indicator light approx. 0.5 sec. (25°C {77 OF}) wiring harness
Over 0.5 seconds (25°C {77 OF})
B+
• Glow indicator light
after turning engine switch ON
234 - - - - -
• Inspect related
235 IG 1 Engine fuse Engine switch ON B+ wiring harness
• Engine fuse
236 - - - - -
237 - - - - -
brake pedal released Below 1.0 • Inspect related
238 Brake light Brake light wiring harness
brake pedal depressed B+
• Brake light
AlC operating Below 1.0 • Inspect related
239 Thermo Thermo switch wiring harness
AlC not operating B+ • Thermo switch
Shift lever neutral position Below 1.0 • Inspect related
240 Neutral Neutral switch wiring harness
Except shift lever neutral position B+
• Neutral switch
241 - - - - -
242 - - - - -
01-408-15
Voltage
(V)
243 - - - - -
LOCK indicator light OFF B+ • Inspect related
wiring harness
244 RFW indicator light LOCK indicator light
LOCK indicator light ON Below 1.0
• Instrument cluster
(LOCK indicator
light)
245 - - - - -
246 - - - - -
247 - - - - -
248 - - - - -
249 - - - - -
250 - - - - -
251 - - - - -
252 - - - - -
Lock solenoid valve operating Below 1.0 • Inspect related
253 Lock solenoid valve Lock solenoid valve wiring harness
Lock solenoid valve not operating B+
• Lock solenoid valve
Free solenoid valve operating Below 1.0 • Inspect related
254 Free solenoid valve Free solenoid valve wiring harness
Free solenoid valve not operating B+ • Free solenoid valve
255 - - - - -
Malfunction indicator light ON Below 1.0 • Inspect related
Malfunction wiring harness
256 MIL
indicator light Malfunction indicator light OFF B+ • Malfunction
indicator light
257 - - - - -
RFW main switch released (OFF) B+ • Inspect related
258 RFW main switch RFW main switch RFW main switch depressed wiring harness
Below 1.0
(ON) • RFW main switch
Inspection Using An Oscilloscope (Reference)

Fuel injector signal
PCM terminals
• Fuel injection (#1): 125, 174 (+)-body ground (-)
• Fuel injection (#3): 101,173 (+)-body ground (-)
Oscilloscope setting
• 20 V/DIV (Y), 20 ms/DIV (X), DC range 1
, 1 1
- -I- - -1- - " 1 - -
1
1 1
- -I- - -1- - -1- - -I - - .. - -
Vehicle condition 1
1
,
1
1
1
I
I
I
I
I
I
I
I
I
I
- -r - -,- -.,-- - -r- - -1- - . , - - , - - T - -
• Idle after warm up 1 1 1 I
I
I
I
1
I
I
I
I
I
- -r1 - -1-1 -"1--
1
- -r - -1- - ., - - , - - 1 - -
1 1 , I I I I I
- _1- __ , ___I __
1
1
1
1
,
1
--:- --:- --:- - ~ --+--
I 1 I I I
DBG140BWB105
CMP signal
PCM terminals
1 1 1 I I I I I
• 160 (+)-body ground (-) 1 1
- -1- --1- - , - -
1 I I I I I
- -1- - -,- - ., - - , - - T - -
Oscilloscope setting 1 1
__ I ___ I __ J __
1 I
I
I
I
I
I
- -.- - -1- - -,- -
I
I
I
I
"i - - T - -
• 2 V/DIV (Y), 50 ms/DIV (X), DC range
1 1
_ _ 1___ I__ J
1
,...----, __ 1___ 1__ _J __ l __
1 1 1 I t I I
Vehicle condition _ _1
I.. __ 1, __ ..I1 I I
__ L __ I__
I I
_.J __ ..L __
• Idle after warm up

1 1 , I I I I
ov ..
1
-->---1---<
1 1
1
1
,
--1---1--
I
I I
I I I
_-1 __ .... __
I I
1 1 1 I I I I
- -t- - -1- -"'1-- - -I- - -1- - "i- - -1- - .. - -
1 1 1 I I I I I
--r--,--,--
1
1
1
1
1
1
I I I I I
- -r - -1- - . , - - , - - T - -
I I I I I
1 1
- -r - -,- - -.--
1 1
1
1
--I--l--'--'--i--
I
I
I
I
I
I I
I I
I
- _1- __ 1___, __ I I I I I
1 1 1 - -.- - -.- - -.- -"j - - "i - -
, , 1 •• I I •
DBG140BWB101
01-408-16
VBC solenoid valve signal
PCM terminals
• 178 (+)-body ground H
I I I I I I t I I I I I
--r-'--'--'--T--r--r--r-'--'--'--T--
I I I I I I I I I I I I
Oscilloscope setting I I I I I
--~-~--~--4--+--~--~--~-~--~--4--+--
I I I I I I I
• 10 V/DIV (Y), 2 ms/DIV (X), DC range __ I,___ I, __ JI __ .JI __ .1I __ 1.

I I I I I I
I
__ IL __ I'- __ ,I __ JI __ JI __ .1I __
I I I I I I
Vehicle condition __ IL_~
I ___ ~
I __ I __ LI
~ _L __ IL __ II __ J ~
I _ I __
__ ~

I t I I I I I I I I
I I I I I I I I I I
ov ..Il-...., -...,~, , , , - i ......--...........
I I I I I I I
--~--1--4--~--~--~--~--~-~--4--~--4--
- -r - -,- - , - - , - -"T - - T - - i - - , - -,- - . . , - - , - -"T - -
1 I I I I I I I I I I I
I I I I I I I I I t i l
- -,- - -,- - -,- -,- -, - - r - - r - -.- - -,- -1-- 1 - -, --
I I I I I 1 I I I I I I
--:- --:- --:- - ~ --4 -- +-- t --:- --:- --:- --{- -4--
Fuel Metering Valve signal

PCM terminals
• 179 (+)-body ground (-) I I I , , I , I , I I I
--r-~--'--'--T--r--r--r-'--'--'--T--
I I , , I , I I , I 1 I
--~-~--~--i--+--.--~--~-~--~--~--+--
• 10 V/DIV (Y), 2 ms/DIV (X), DC range __ 1L __ 1I__ I 1
J __ J __ lI __ l1 __ L
I I
__ L __1I__ J , __ J1 __ l1 __
Vehicle condition
I 1 I 1 1 , I 1 I 1 1 1
I 1 I 1
_ ~_ ~ __ L _L ~_
• Idle after warm up, AlC ON

I , 1 1 1
I , 1 1 I
ov" -"
I 1 ,
,t--r,
I 1 I 1 I
--~-~--~--~--+--~--~--~-~--~--~--+--
I I I 1 1 I I I 1 I 1 I
1 , 1 1 1 I til 1 1 1
- -r - -,- - ,- -, - - 'T - - r - - r - -r - -1- - . , - - . , - - -r --
l i t 1 I I , I I 1 I 1
1 I I ,
- -.- - -,- -"1- - , - - i - -
1 , I 1
I
I
r -- r --.- --,- -,- -, -- i
1
1
I
1
1
1
,
,
1
I
,
I
1
I
--
- -:- - -:- - -:- - -i -- t -- t - - ~ - -:- - -:- - -:- -,- -1--

I 1 I [ I I 1 , 1 I [ I
DBG140BWB103
Vehicle speed signal

PCM terminals I 1 I 1 1 I 1 I , [ I [
• 184 (+)-body ground (-)
t + ~ ~! -~
--r-'--'--'--T--r--r--r-'--,--'--T--
I , , l i t I 1 1 I I I
-t
r
~ ~:- ~ ~;~ ~ !~+- ~ t~ ti- ~

I 1 I I I L I I , 1 I
4
• 1 V/DIV (Y), 2.5 ms/DIV (X), DC range , I I L l 1 , I 1 1
Vehicle condition 1 I
__ 1_
I I 1
.J _ _ _ _ ..L _L_
1 ,
L _ _ _ _ ,_
I I
J ____
1
~ _
• Vehicle speed is 32 km/h {20 mph}.

1 I I' 1 'I I
1 1
--1- __ +1 1 1
~ __ '1
--1- ____ +I -
~
--1- ~ ,--i ~ ~--:~ H -

I I' 1 I I 1 1 1 I
ov .. ~: ~--
, I 1 1 I I , , 1 1 1 1
- -r - -,- -.,- -"1 - - 'T - - T - - r - -, - -,- -.,- -, - - 'T - -
1 I , 1 1 I 1 1 1 I 1 1
I I 1 1 I 1 1 , , I I I
- -.- - -,- -1- - , - - i - - T - - r - -.- - -1- - . , - - , - - i --
1 I I , I 1 1 1 , I I ,
- -:- - -:- - -:- -,- - t - - t - - ~ --:- - -:- - -:- -,- - t --

, 1 1 I 1 I 1 1 I [ 1 ,
DBG140AWB184
CKP signal
PCM terminals
, I t i l I t I I , 1 1
• 192, 193 (+)-body ground (-) --r--r--'--'--T--r--r--r--I--,--'--T--
I I 1 I 1 I rI , 1 1 1
1 I , I , 1 I , 1 1 I 1
- -. - -(- - -:- - -:- -,- - -i - - +--

--:-r - -:- --:-, - ~ -~:
• 5 V/DIV (Y), 2 ms/DIV (X), DC range i-: ~ - - +- - t -
I 1 1
I 1- - - -:
1
-
I
-
1 I
Vehicle condition 1 I [I
__ L
1 1
' __
1
J

j , j t ~, -,~ ~ ~ ~
1 I I I I 1
OV.. ~ r
I I 1 1 , 1 1 1 1 1 [ 1
1 I , 1 I 1 1 1 1 1 , I
- - , - -,- - , - - , - - 'T - - r - - r - -, - -1- - . , - - , - - -r --
, 1 , 1 I 1 I , 1 I I I
- -:- - -:- -~- - -i - - t -- t - - ~ - -~ - -:- -~- -~ - - t --

1 1 1 1 I I I tIl , ,
- -:- - -:- --:- -,- - t - -t - - ~ - -:- - -:- - -:- -,- - t --

1 I til , I , I 1 I 1
DBG140BWB104
01-408-17
Using the current diagnostic tool
Caution
• The PCM terminal voltage vary with change in measuring conditions and vehicle conditions.
.'
Always carry out a total inspection of the input systems, output systems, and PCM to determine
the cause of trouble. Otherwise, diagnosis will be incorrect.
Note
• PIDs for the following parts are not available on this model. Go to the appropriate part inspection page.
Fuel injector
CMP sensor
EGR valve position sensor
EGR solenoid valve
IAT sensor No.2
1. Connect the current diagnostic tool to the DLC. (See 01-02B-7 ON-BOARD DIAGNOSTIC TEST [WL-C, WE-
C].)
2. Measure the PID value .
• If PID value is not within the specification, follow the instructions in ACTION column.
Note
• The PID/DATA MONITOR function monitors the calculated value of the input/output signals in the PCM.
Therefore, an output device malfunction is not directly indicated as a malfunction of the monitored value
for the output device. If a monitored value of an output device is out of specification, inspect the monitored
value of the input device related to the output control.
• For input/output signals except those of the monitoring items, use a voltmeter to measure the PCM
terminal voltage.
• The simulation items that are used in the ENGINE CONTROL SYSTEM OPERATION INSPECTION are
as follows.
- ACCS, EGRV2, GP_LMP, GPC, IASV, IASV2, INL1, INJ_2, INJ_3, INL4, SEGRP, VBCV
PIO Monitor Table (Reference)

Monitor item PCM
Unit/Condition Condition/Specification (Reference) Inspection item
(Definition) terminal
AAT
(Ambient temperature)
°C Ambient temperature -
AC_REQ Refrigerant pressure switch is off: Off
On/Off AlC switch 239
(AIC request signal) Others: On
ACCS Inspect following PIDs:
(Air conditioning AlC switch ON and fan switch ON: On START_SW, CPP, CPP/PNP,
On/Off 128
compressor cycling Others: Off IVS, AC_REQ, APS1, APS2,
switch) ECT, RPM
APP
Accelerator pedal released: 0 % Inspect following PIDs: APP1 ,
(Accelerator pedal % 209,222
Accelerator pedal depressed: 100 % APP2
position)
Accelerator pedal released: 0%
%
Accelerator pedal depressed: 100%
APP1
(Accelerator pedal Accelerator pedal released: APP sensor 222
position sensor No.1 ) Below 1.0 V
V
Accelerator pedal depressed:
Approx. 3.6 V
Accelerator pedal released: 0%
%
Accelerator pedal depressed: 100%
APP2
(Accelerator pedal Accelerator pedal released: APP sensor 209
position sensor No.2) Below 1.0 V
V
Accelerator pedal depressed:
Approx. 3.6 V
Inspect following PIDs:
ARPMDES No load: 695-745 rpm IVS, AC_REQ, IAT, IAT2, ECT,
(Target engine speed)
RPM
AlC ON: 725-775 rpm BOOST_DSD, FRP, FRP_A,
-
RPM,VSS
BARO
I
kPa Bar I psi Indicate Barometric pressure
BARO 103 kPa {1.03 Bar, 14.9 psi}: BARO sensor -
(Barometric pressure) V
Approx. 4.0 V
01-408-18
Monitor item PCM

BOO Brake pedal released: Off
On/Off Brake switch 238
(Brake switch) Brake pedal depressed: On
CPP Clutch pedal released: On
On/Off CPP switch 228
(CPP switch) Clutch pedal depressed: Off
DTCCNT Number of DTCs stored in the PCM is Perform applicable DTC
(DTC count)
- displayed. troubleshooting.
-
°C Engine coolant temperature is displayed
ECT ECT 30°C {86 OF}: Approx. 2.6 V
(Engine coolant ECT 40°C {104 OF}: Approx. 2.1 V Inspect ECT sensor. 167
temperature) V
ECT 50°C {122 OF}: Approx. 1.8 V
ECT 60°C {140 OF}: Approx. 1.4 V
EGRV2
Engine switch ON: ON Inspect EGR control solenoid
(EGR control solenoid On/Off 177
Idle: OFF valve.
valve)
Engine switch ON: 1.35 A Inspect following PIDs:
FIP_FL A
Idle: Approx. 1.45 A IVS, AC_REQ, IAT1, IAT2, ECT,
(Supply pump flow 179
Engine switch ON: 14.6 % BOOST_DSD, FRP, FRP _A,
control) %
Idle: 37.6 % RPM,VSS
FIP_SCV Engine switch ON: Approx. 580 mA IVS, AC_REQ, IAT1, IAT2, ECT,
A 179
(Fuel metering valve) Idle: 1.45 A BOOST_DSD, FRP, FRP _A,
RPM, VSS
FLT
°C Fuel temperature is displayed. Fuel temperature sensor 115
(Fuel temperature)
Engine switch ON: 0 kPa {O psi, 0 Bar}
Idle: Approx. 32 MPa (WL-C),
FRP Approx. 33 MPa {330 Bar, 4,786 psi}
kPa Bar psi Fuel pressure sensor 140
(Fuel pressure sensor) (WE-C)
2,000 rpm: Approx. 58 MPa {580 Bar,
8,412 psi}
GP_LMP Glow indicator light Off: Off
On/Off 233
(Glow indicator light) Glow indicator light ON: On
13s from when engine switch is turned
to ON position with ECT at 20 °C{68 OF}
of less
GPC ECT, BOOST_DSD, VSS
On/Off Cranking: On (ECT at 60 O{140 OF} or 182
(Glow plug relay)
less)
Idle: Off (2m or more after engine is
started)
IASV
Engine switch ON: OFF
(Intake shutter On/Off 152
Idle: OFF (WL-C), ON (WE-C)
solenoid valve (half))
Intake air shutter valve
IASV2
(Intake shutter On/Off Engine switch ON: OFF 155
solenoid valve (full))
IAT 30°C {86 OF}: Approx. 1.4 V
V
(Intake air 50°C {104 OF}: Approx. 1.2 V
IAT sensor 141
temperature (lAT
sensor No.1)) °C Intake air temperature is display
INGEAR
Neutral: On
(Load/no load On/Off Inspect following PIDs: CPP 240
Others: Off
condition)
IVS CTP: Idle
Idle/Off Idle APP sensor 161
(Idle switch) Others: Off Idle
LOAD Engine switch ON: 0%
(Engine load)
%
Idle: Approx. 22 %
MAF sensor -
Engine switch ON: 2 g/s
g/s
MAF Idle: Approx. 8 g/s
MAF sensor 190
(Mass airflow amount) Engine switch ON: Below 1.0 V.
V
Idle: Approx. 1.76 V
01-408-19
Monitor item PCM

MAP
I
kPa Bar I psi Manifold absolute pressure is displayed
Engine switch ON: Approx. 1.65 V MAP sensor 189
(Boost sensor) V
Idle: Approx. 1.65 V
MIL Engine switch ON: On
Perform applicable DTC
(Malfunction indicator On/Off 256
Idle: Off troubleshooting.
lamp)
MIL_DIS
(The distance travelled
Km Indicate the travelled distance since the MIL illuminated -
since the MIL was
activated)
Engine switch ON: 0 RPM
RPM
(Engine speed)
rpm
Idle I No load: 695-745 rpm CKP sensor 193
AlC ON: 725-775 rpm
SEGRP DSD Engine switch ON: Approx. 4.68 %
(Desired EGR valve % Idle: Approx. 78 % Desired SEGRP valve position -
position) Engine speed 2,000 rpm: Approx. 94 %
SELTESTDTC
Perform applicable DTC
(Diagnostic trouble - - -
troubleshooting
codes)
Inspect following PIDs: IVS,
VBCV Engine switch ON: Approx. 4.99 %
% MAF, ECT, RPM 178
(VBC solenoid valve) Idle: Approx. 79 %
Inspect VBC solenoid valve.
VPWR
Battery 201,
(Module supply V Indicate the battery positive voltage
Main relay 203,205
voltage)
VSS Perform applicable DTC
km/h Vehicle speed is displayed 184
(Vehicle speed) troubleshooting.
PCM CONFIGURATION [WL-C, WE-C]

dcf014018880w03
Using PDS/IDS
1. Connect the PDS/IDS to DLC-2.
1. Select the "Module Programming".
1. Select "Programming".
2. Select "Module Programming".
3. Then, select the "Programmable Module
Installation", "PCM" and perform procedures
DBG110BWBA01
Note
• If the PCM is replaced with a new one, the
PCM stores DTCs P0602 and P1675, illuminates the MIL even though no malfunction is detected. When
the configuration is completed, DTCs P0602 and P1675 are cleared.
4. Retrieve DTC's using the PDS/IDS, then verify if DTCs are present.
• If a DTC is present, perform the applicable DTC inspection.
01-408-20
CONTROL SYSTEM [WL-C, WE .. C]
Using WDS
1. Connect the WDS to DLC-2.
2. Set up the WDS (including the vehicle
recognition).
3. Select "Module Programming."
4. Select "Programmable Module Installation."
5. Select "PCM" and perform procedures according
to directions on the WDS screen.
Note
• If the PCM is replaced with a new one, the
PCM stores DTCs P0602 and P1675,
illuminates the MIL even though no
malfunction is detected. When the
configuration is completed, DTCs P0602
and P1675 are cleared.
6. Retrieve DTC's using the WDS, then verify if DTCs are present.
FUEL INJECTOR CODE PROGRAM [WL-C, WE-C]

Using PDS/IDS
1. Select the "Module Programming".
1. Select "Programming".
3. Then, select the "Programmable Parameters",
"Injector Correction Factors" and perform
IDS screen.
DBG110BWBA01
4. Retrieve DTC's using the PDS/IDS, then verify if
DTCs are present.
Using WDS
recognition).
4. Select "Programmable Parameters".
5. Select "Injector Correction Factors" and perform
procedures according to directions on the WDS
screen.
6. Retrieve DTC's using the WDS, then verify if
DTCs are present.
• If a DTC is present, perform the applicable
DTC inspection.
DBG110BWBA01
01-408-21
PCM DATA RESET [WL-C, WE-C]
dcf014018880w05
Using PDS/IDS
'2. After the vehicle is identified, select the following
2. Select the "Data Reset".
2. Select "Data Reset".
3. Then, select the "PCM" and perform procedures
4. Perform the data reset according to the directions
DBG110BWBA01
on the PDS/IDS screen.
5. Retrieve DTC's using the PDS/IDS, then if that
DTCs are present.
Using WDS
recognition).
3. Select "Powertrain".
5. Select "PCM" and perform procedures according
to directions on the WDS screen.
DTCs are present.
DTC inspection.
DBG110BWBA01
MASS AIR FLOW (MAF) SENSOR DATA RESET [Wl-C, WE-C]

dcf014018880w06
Using PDS/IDS
2. Select the "Data Reset".
3. Then, select the "MAF sensor" and perform
IDS screen.
DBG110BWBA01
4. Perform the data reset according to the directions
on the PDS/IDS screen.
5. Retrieve DTC's using the PDS/IDS, then verify if DTCs are present.
01-408-22
Using WOS
recognition).
3. Select "Powertrain".
5. Select "MAF sensor" and perform procedures
according to directions on the WDS screen.
DTCs are present.
DTC inspection.
MAIN RELAY INSPECTION [WL-C, WE-C]

1. Verify the continuity between the main relay
terminals.
MAIN RELAY
0-0 : Continuity rcfAl

Step
Terminal [ill]
A B C D
1 0 -0
2 B+ GROUND 0 -0
DBG113BWB321
DBG113AWB3R
main relay.
MASS AIR FLOW (MAF) SENSORIINTAKE AIR TEMPERATURE (IAT) SENSOR NO.2 INSPECTION [WL-C,
WE-C]
dcf014013215w02
Note
• Perform the following inspection only when directed.
MAF Sensor Voltage Inspection

2. Set the current diagnostic tool and monitor the MAF PID.(See 01-028-8 PID/DATA Monitor And Record
Procedure.)
• If not as specified, perform the "Circuit Open/Short Inspection".
- If there is no open/short circuit, replace the MAF sensor/IAT sensor No.2.01-138-3 INTAKE-AIR
SYSTEM REMOVAUINSTALLATION [WL-C, WE-C].)
MAF PIO (Reference)

below 1.0 V
3. Start the engine and warm up the engine completely.

4. Monitor the MAF PID at idle.
- If there is no open/short circuit, replace the MAF sensor/IAT sensor No.2.01-138-3INTAKE-AIR
SYSTEM REMOVAUINSTALLATION [WL-C, WE-C].)
MAF PIO (Reference)

1.6-2.0 V
01-408-23
1. Disconnect the MAF sensor/lAT sensor No.2 connector.
2. Disconnect the PCM connector.(See01-40B-9 PCM REMOVAUINSTALLATION [WL-C, WE-C]
• If there is an open or short circuit, repair or r----------------------,
replace wiring harnesses. MAF SENSOR/IAT SENSOR NO.2
~EIDmBIA~
I~~I
DBG140AWB302
PCM
124 123 122 121 120 119 118 117 116 115 114 113 112 111 110 109 108 107 106 105 104 103 102 101
148 147 146 145 144 143 142 141 140 139 138 137 136 135 134 133 132 131 130 129 128 127 126 125
172 171 170 169 168 167 166 165 164 163 162 161 160 159 158 157 156 155 154 153 152 151 150 149
196 195 194 193 192 191 190 189 188 187 186 185 184 183 182 181 180 179 178 177 176 175 174 173
DBG113BWB319
Open circuit
• Power circuit (MAF sensor/lAT sensor No.2 connector terminal A and main relay connector terminal D)
• Signal circuit (MAF sensor/lAT sensor No.2 connector terminal C and PCM connector terminal 190)
• Ground circuit (MAF sensor/lAT sensor No.2 connector terminal Band PCM connector terminal 169)
Short circuit
• MAF sensor/lAT sensor No.2 connector terminal A and main relay connector terminal D short to ground
• MAF sensor/lAT sensor No.2 connector terminal C and PCM connector terminal 190 short to ground
IAT Sensor No.2 Resistance Inspection

1. Disconnect the MAF sensor/lAT sensor No.2 connector.
01-408-24
2. Measure the resistance between MAF sensor/IAT
sensor No.2 terminals D and E using an
ohmmeter.
• If not as specified, replace the MAF sensor/
IAT sensor NO.2. 30
• If as specified, carry out the "Circuit Open/ 20 ~
~ 13.6-18.4 kilohm
Short Inspection".
E 10 ~
.c
Specification 0 7
Ambient temperature (Oe eF}) Resistance (kilohm) ~ 5 ~"
!'\.~
w \..~
20 {68} 2.21-2.69 ()
3
z ~ ~ 2.21-2.69 kil ohm
60 {140} 0.493-0.667 ~ 2
~
en
Ci5
w ~
a:
0.7
0.493 0.667
0.5 kilohm 1'................
0.3 I I ~
0.2 -20 0 20 40 60 80
{-4} {32} {68} {104} {140} {176}
INTAKE AIR TEMPERATURE rC {'F})
~EIDfflBIA~
I~~I
DBG140AWB303
1. Disconnect the MAF sensor/IAT sensor No.2 connector.
2. Disconnect the PCM connector.(See01-40B-9 peM REMOVAUINSTALLATION [WL-C, WE-C].)
• If there is an open or short circuit, repair or ,---------------------,
replace wiring harnesses. MAF SENSORIIAT SENSOR NO.2
~EIDfflBIA~
I~~I
DBG140AWB302
PCM
124 123 122 121 120 119 118 117 116 115 114 113 112 111 110 109 108 107 106 105 104 103 102 101
148 147 146 145 144 143 142 141 140 139 138 137 136 135 134 133 132 131 130 129 128 127 126 125
172 171 170 169 168 167 166 165 164 163 162 161 160 159 158 157 156 155 154 153 152 151 150 149
196 195 194 193 192 191 190 189 188 187 186 185 184 183 182 181 180 179 178 177 176 175 174 173
DBG113BWB319
01-408-25
Open circuit
• Signal circuit (MAF sensor/IAT sensor No.2 connector terminal D and PCM connector terminal 188)
• Ground circuit (MAF sensor/IAT sensor No.2 connector terminal E and PCM connector terminal 154)
Short circuit
• MAF sensor/I AT sensor No.2 connector terminal D and PCM connector terminal 188 to GND
INTAKE AIR TEMPERATURE (IAT) SENSOR NO.1 INSPECTION [WL-C, WE-C]

dcf014018842w02
Note
1. Disconnect the boost sensor/IAT sensor No.1 connector.
2. Measure the resistance between IAT sensor No.1
terminals A and B using an ohmmeter. IAT SENSOR NO.1 CHARACTERISTIC (REFERENCE)
• If not as specified, replace the boost sensor/ 18
IAT sensor No.1. 16
'E14
Short inspection". ..c:
0.12
:2
Specification ;U-10
Water temperature eC eF}) Resistance (kilohm) ~ 8
20 {68} 2.41-2.61 j:5
CI) 6
80 {176} 0.32-0.34 1i5
w 4
II
2
0_
20 -10 0 10 20 30 40 50 60 70 80
{-4} {14} {32} {50} {68} {86} {104}{122}{140}{158}{176}
INTAKE AIR TEMPERATURE (OC {OF} )
DBG140BWB304
BOOST SENSORJIAT SENSOR NO.1
DBG140AWB556

2. Disconnect the PCM connector.(See01-40B-9 PCM REMOVAL/INSTALLATION [WL-C, WE-C].)
3. Inspect for an open or short circuit in the following siring harnesses.
• If there is an open or short circuit, repair or ,------------------------,
replace wiring harnesses. BOOST SENSORJIAT SENSOR NO.1
milla
I~~ I DBG140BWB301
01-408-26
PCM
124 123 122 121 120 119 118 117 116 115 114 113 112 111 110 109 108 107 106 105 104 103 102 101
148 147 146 145 144 143 142 141 140 139 138 137 136 135 134 133 132 131 130 129 128 127 126 125
172 171 170 169 168 167 166 165 164 163 162 161 160 159 158 157 156 155 154 153 152 151 150 149
196 195 194 193 192 191 190 189 188 187 186 185 184 183 182 181 180 179 178 177 176 175 174 173
Open circuit
• Signal circuit (8oost sensor/IAT sensor No.1 connector terminal A and PCM connector terminal 111)
• Ground circuit (8oost sensor/I AT sensor No.1 connector terminal 8 and PCM connector terminal 141)
Short circuit
• IAT sensor No.1 connector terminal A and PCM connector terminal 111 to ground
BOOST SENSOR INSPECTION [WL-C, WE-C]

dcf014018212w02
Note
Visual Inspection
1. Inspect the boost sensor for damage and cracks.
• If there is any malfunction, replace the boost sensor/I AT sensor No.1.
• If there is not any malfunction, perform the "Voltage Inspection".
Voltage Inspection
2. Set the current diagnostic tool and monitor the MAP PID.(See 01-028-8 PID/DATA Monitor And Record
Procedure.)
• If not as specified, perform the "Circuit Open/Short Inspection". .
- If there is no open/short circuit, replace the boost sensor/IAT sensor No.1. (See 01-138-3 INTAKE-AIR
SYSTEM REMOVAUINSTALLATION [WL-C, WE-C).)
MAP PIO (Reference)

Approx. 1.65 V [Atmospheric pressure 101 kPa {757.5 mmHg, 29.8 inHg}]

4. Monitor the MAP PID using the current diagnostic tool at idle.
- If there is no open/short circuit, replace the boost sensor/IAT sensor No.1. (See 01-138-3 INTAKE-AIR
SYSTEM REMOVAUINSTALLATION [WL-C, WE-C).)
MAP PIO (Reference)

Approx. 1.65 V [Atmospheric pressure 101 kPa {757.5 mmHg, 29.8 inHg}]
01-408-27
1. Disconnect the PCM connector. (See 01-40B-9 PCM REMOVAL/INSTALLATION [WL-C, WE-C).)
3. Inspect for open/short circuit in the following wiring harnesses.
• If there is open/short circuit, repair or replace ,----------------------,
wiring harnesses. BOOST SENSORIIAT SENSOR NO.1
ffiWm6ID
I~~ I DBG140BWB301
PCM
124 123 122 121 120 119 118 117 116 115 114 113 112 111 110 109 108 107 106 105 104 103 102 101
148 147 146 145 144 143 142 141 140 139 138 137 136 135 134 133 132 131 130 129 128 127 126 125
172 171 170 169 168 167 166 165 164 163 162 161 160 159 158 157 156 155 154 153 152 151 150 149
196 195 194 193 192 191 190 189 188 187 186 185 184 183 182 181 180 179 178 177 176 175 174 173
DBG113BWB319
Open circuit
• Power circuit (Boost sensor/IAT sensor No.1 connector terminal D and PCM connector terminal 189)
• Signal circuit (Boost sensor/IAT sensor No.1 connector terminal C and PCM connector terminal 133)
• Ground circuit (Boost sensor/IAT sensor No.1 connector terminal A and PCM connector terminal 111)
Short circuit
• Boost sensor/IAT sensor No.1 connector terminal A and PCM connector terminal 111 short to power supply
• Boost sensor/IAT sensor No.1 connector terminal C and PCM connector terminal 133 short to power supply
• Boost sensor/IAT sensor No.1 connector terminal C and PCM connector terminal 133 short to body ground
• Boost sensor/IAT sensor No.1 connector terminal D and PCM connector terminal 189 short to power supply
• Boost sensor/IAT sensor No.1 connector terminal D and PCM connector terminal 189 short to body ground
ACCELERATOR PEDAL POSITION (APP) SENSOR INSPECTION [WL-C, WE-C]

dcf014041609w02
Note
Voltage Inspection
1. Verify that the APP sensor is installed to the accelerator pedal properly.
2. Visually inspect all accelerato[ pedal components for looseness.
01-408-28
3. Check the power circuit voltage.
(1) Verify that the voltage between the APP
sensor terminals A (power circuit) and D
(ground circuit) is 4.9-5.1 V.
APP SENSOR
APPSENSOR
DBG140AWB311
4. Verify that the voltage between the APP sensor terminals B-D, and C-D is as shown below according to the
accelerator pedal conditions.
• If not as specified, carry out the "Circuit
Open/Short Inspection:' APP SENSOR
If there is no open/short circuit, WIRING HARNESS-SIDE CONNECTOR
replace the APP sensor.(See01-13B-
3 INTAKE-AIR SYSTEM REMOVAU
INSTALLATION [WL-C, WE-C]
[ 1: I C I B I A: IJ
0
Specification (Reference)
I~~I
Accelerator pedal
Output voltage (V)
condition
Fully released 0.4-0.8
Gradually depressed Increases linearly DBG140AWB311
Fully depressed 3.4-3.8
01-408-29
2. Disconnect the APP sensor connector.
• If there is an open or short circuit, repair or ,-------------------,
replace wiring harnesses. APP SENSOR
DBG140AWB311
PCM
219 218 217 216 215 214 213 212 211 210 209 208 207
202 201
232 231 230 229 228 227 226 225 224 223 222 221 220
204 203
245 244 243 242 241 240 239 238 237 236 235 234 233
206 205
258 257 256 255 254 253 252 251 250 249 248 247 246
DBG113BWB318
Open circuit
• Power circuit (APP sensor connector terminal A and PCM connector terminal 213)
• Signal circuit (APP sensor connector terminal 8 and PCM connector terminal 222)
• Signal circuit (APP sensor connector terminal C and PCM connector terminal 209)
• Ground circuit (APP sensor connector terminal D and PCM connector terminal 212)
Short circuit
• APP sensor connector terminal A and PCM connector terminal 213 short to ground
• APP sensor connector terminal 8 and PCM connector terminal 222 short to power supply
• APP sensor connector terminal 8 and PCM connector terminal 222 short to ground
• APP sensor connector terminal C and PCM connector terminal 209 short to power supply
• APP sensor connector terminal C and PCM connector terminal 209 short to ground
• APP sensor connector terminal D and PCM connector terminal 212 short to power supply
IDLE SWITCH INSPECTION [WL-C, WE-C]

dcf014066470w02
Note
1. Disconnect the idle switch connector.
01-408-30
2. Inspect continuity between the idle switch
terminals A and 8 using an ohmmeter.
• Irnot as specified, replace the idle switch. IDLE SWITCH
- If as specified, carry out the "Circuit
Open/Short Inspection". OFF - : - ON
,,,
,
Specification
Accelerator Continuity
Idle switch
pedal condition
PUSH ROD
Push the rod Released Continuity
Except above Depressed No continuity .
Circuit open/short inspection

1. Disconnect the idle switch connector.
2. Disconnect the PCM connector. (See 01-408-9 PCM REMOVAUINSTALLATION [WL-C, WE-CD
• If there is an open or short circuit, repair or r----------------------,
replace wiring harnesses.
IDLE SWITCH
DBG140AWB313
PCM
124 123 122 121 120 119 118 117 116 115 114 113 112 111 110 109 108 107 106 105 104 103 102 101
148 147 146 145 144 143 142 141 140 139 138 137 136 135 134 133 132 131 130 129 128 127 126 125
172 171 170 169 168 167 166 165 164 163 162 161 160 159 158 157 156 155 154 153 152 151 150 149
196 195 194 193 192 191 190 189 188 187 186 185 184 183 182 181 180 179 178 177 176 175 174 173
DBG113BWB319
Open circuit
• Power circuit (idle switch connector terminal A and PCM connector terminal 161)
• Ground circuit (idle switch connector terminal 8 and ground.)
Short circuit
• Idle switch connector terminal A and PCM connector terminal 161 short to ground
01-408-31
FUEL TEMPERATURE SENSOR INSPECTION [WL-C, WE-C]
dcf014018843w02
Note
1. Remove the supply pump. (See 01-148-11 SUPPLY PUMP REMOVAL/INSTALLATION [WL-C, WE-C].)
2. Measure the resistance between the fuel temperature sensor terminals using an ohmmeter.
• If not as specified, repair the supply pump. (See 01-148-13 SUPPLY PUMP INSPECTION [WL-C, WE-C].)
Short Inspection".
Specification
Ambient temperature
(OC {OF}) Resistance (kilohm)
-10 {14} 8.244-10.661

20 {68} 2.262-2.760
80 {176} 0.304-0.342
DBG140BWB302

1. Disconnect the PCM connector. (See 01-408-9 PCM REMOVAL/INSTALLATION [WL-C, WE-CD
• If there is open/short circuit, repair or replace r----------------------,
wiring harness. FUEL TEMPERATURE SENSOR
DBG140BWB303
PCM
124 123 122 121 120 119 118 117 116 115 114 113 112 111 110 109 108 107 106 105 104 103 102 101
148 147 146 145 144 143 142 141 140 139 138 137 136 135 134 133 132 131 130 129 128 127 126 125
172 171 170 169 168 167 166 165 164 163 162 161 160 159 158 157 156 155 154 153 152 151 150 149
196 195 194 193 192 191 190 189 188 187 186 185 184 183 182 181 180 179 178 177 176 175 174 173
DBG113BWB319
Open circuit
• Power circuit (Fuel temperature sensor connector terminal A and PCM connector terminal 115
• Ground circuit (Fuel temperature sensor connector terminal 8 and PCM connector terminal 170
Short circuit
• Fuel temperature sensor connector terminal A and PCM connector terminal 115 short to power
• Fuel temperature sensor connector terminal A and PCM connector terminal 115 short to ground
• Fuel temperature sensor connector terminal 8 and PCM connector terminal 170 short to power
01-408-32
FUEL PRESSURE SENSOR INSPECTION [WL-C, WE-C]
dcf014018213w01
Note
Voltage Inspection
2. Measure the voltage between fuel pressure sensor terminals A and 8 using a voltmeter at idle .
- If there is no open/short circuit, replace the common rail.
Specification (Reverence)
Approx. 1.25 V

DBG140BWB305
3. Turn off the engine and wait three minutes. FUEL PRESSURE SENSOR CHARACTERISTIC (REFERENCE)
4. Turn the engine switch to the ON position (Engine 5.0
off).
~ 4.0
V r--
5. Measure the voltage between fuel pressure V I-""
sensor terminals A and 8 using a voltmeter. ~ 3.0 /
• If not as specified, perform the "Circuit Open/ !j 2.0
Short Inspection". V
~ 1.0 /
- If there is no open/short circuit, replace ----
the common rail. 0.00 40 80 120 160 200
{O,O} {4.1, {8.2, {12.2, {16.3, {2.0,
Specification (Reference) 5,801} 11,603} 17,404} 23,206} 29007}
FUEL PRESSURE (MPa {kgf/m2, psi}))
0.494-0.506 V
DBG140AWB558

1. Disconnect the fuel pressure sensor connector.
2. Disconnect the PCM connector. (See 01-408-9 PCM REMOVAUINSTALLATION [WL-C, WE-C])
01-408-33
• If there is open/short circuit, repair or replace r--------------------,
wiring harnesses. FUEL PRESSURE SENSOR
DBG140BWB305
PCM
124 123 122 121 120 119 118 117 116 115 114 113 112 111 110 109 108 107 106 105 104 103 102 101
148 147 146 145 144 143 142 141 140 139 138 137 136 135 134 133 132 131 130 129 128 127 126 125
172 171 170 169 168 167 166 165 164 163 162 161 160 159 158 157 156 155 154 153 152 151 150 149
196 195 194 193 192 191 190 189 188 187 186 185 184 183 182 181 180 179 178 177 176 175 174 173
DBGl13BWB319
Open circuit
• Power circuit (Fuel pressure sensor connector terminal C and PCM connector terminal 109)
• Signal circuit (Fuel pressure sensor connector terminal 8 and PCM connector terminal 140)
• Ground circuit (Fuel pressure sensor connector terminal A and PCM connector terminal 191)
Short circuit
• Fuel pressure sensor connector terminal A and PCM connector terminal 191 short to power supply
• Fuel pressure sensor connector terminal 8 and PCM connector terminal 140 short to power supply
• Fuel pressure sensor connector terminal 8 and PCM connector terminal 140 short to body ground
• Fuel pressure sensor connector terminal C and PCM connector terminal 109 short to power supply
• Fuel pressure sensor connector terminal C and PCM connector terminal 109 short to body ground
ENGINE COOLANT TEMPERATURE (ECT) SENSOR REMOVAUINSTALLATION [WL-C, WE-C]

dcf014018841w03
Warning
• When the engine is hot, it can badly burn. Turn off the engine and wait until it is cool before
removing the ECT sensor.

3. Remove the common rail. (See 01-148-11 SUPPLY PUMP REMOVAUINSTALLATION [WL-C, WE-C].)
4. Remove the ECT sensor. 15.7-23.5 N.m
5. Install in the reverse order of removal. {1.61-2.39 kgf·m,
11.6-17.3 ft·lbf}
DBGl16BWB201
01-408-34
ENGINE COOLANT TEMPERATURE (ECT) SENSOR INSPECTION [WL-C, WE-C]
dcf014018841w04
Note
1. Remove the ECT sensor. (See01-40B-34 ENGINE COOLANT TEMPERATURE (ECT) SENSOR REMOVAL!
INSTALLATION [WL-C, WE-C]
2. Measure the resistance between the ECT sensor
terminals A and B using an ohmmeter.
• If not as specified, replace the ECT sensor.
Short Inspection".
Specification
Resistance
Engine coolant temperature (OC eF})
(kilohm)
20 {68} 2.37-2.53
80 {176} 0.31-0.32
110 {176} 0.137-0.146 DBG140BWB306
ECT SENSOR SIGNAL CHARACTERISTIC (REFERENCE)

10
9
S
~7 \
o
::!6 \
~
w5
()
z4 \
~ \
~3
C/) \
~2
--
r--..,
o -20 0 20 40 60 SO
l- I--
100 120
-
{-4} {32} {6S} {104} {140} {176} {212} {24S}
ENGINE COOLANT TEMPERATURE (OC {OF})
DBG140AWB333
01-408-35
1. Disconnect the PCM connector. (See 01-408-9 PCM REMOVAL/INSTALLATION [WL-C, WE-CD
• If there is an open or short circuit, repair or ,--------EC-T-S-E-N-S-O-R---------,
replace wiring harness. WIRING HARNESS-SIDE CONNECTOR
DBG140BWB307
PCM
124 123 122 121 120 119 118 117 116 115 114 113 112 111 110 109 108 107 106 105 104 103 102 101
148 147 146 145 144 143 142 141 140 139 138 137 136 135 134 133 132 131 130 129 128 127 126 125
172 171 170 169 168 167 166 165 164 163 162 161 160 159 158 157 156 155 154 153 152 151 150 149
196 195 194 193 192 191 190 189 188 187 186 185 184 183 182 181 180 179 178 177 176 175 174 173
DBG113BWB319
Open circuit
• Power circuit (ECT sensor connector terminal A and PCM connector terminal 156)
• Ground circuit (ECT sensor connector terminal 8 and PCM connector terminal 167)
Short circuit
• ECT sensor connector terminal A and PCM connector terminal 156 short to ground
• ECT sensor connector terminal A and PCM connector terminal 167 short to power
CAMSHAFT POSITION (CMP) SENSOR REMOVAUINSTALLATION [WL-C, WE-C]

dcf014018230w01
Caution
• When replacing the CKP sensor, make sure there is no foreign material on it such as metal
shavings. If it is installed with foreign material, the sensor output signal will malfunction resulting
from fluctuation in magnetic flux and cause a deterioration in engine control.

2. Remove the CMP sensor.
CMP sensor tightening torque

7.8-10.8 N·m {80-110 kgf·cm, 70-95
in.lbf}
DBG116BWB202
01-408-36
CAMSHAFT POSITION (CMP) SENSOR INSPECTION [WL-C, WE-C]
dcf014018230w02
Note
• 8efore performing the following inspection, make sure to follow the procedure as indicated in the
troubleshooting flowchart. (See 00-00-5 Troubleshooting Procedure.)
Visual Inspection
1. Remove the CMP sensor. (See 01-408-36 CAMSHAFT POSITION (CMP) SENSOR REMOVAL!
2. Verify that there are no metal shavings on the sensor.
3. Install the CMP sensor. (See 01-408-36 CAMSHAFT POSITION (CMP) SENSOR REMOVAUINSTALLATION
[WL-C, WE-C].)
Voltage Inspection
1. Idle the engine.
Caution
• Water penetrating the connector will cause sensor malfunction. To prevent this, be careful not to
damage the wiring harnesses or the waterproof connector so as to cause water penetration.
2. Measure the output voltage using a oscilloscope .

• If not within the specification, replace the CMP SENSOR
CMP sensor. (See 01-408-36 CAMSHAFT WIRING HARNESS-SIDE CONNECTOR
M£M
POSITION (CMP) SENSOR REMOVAU
• if there is an open or short circuit, repair or
CMP sensor voltage

Terminal
A
Voltage (V)
approx.O
approx.5
Condition
Under any condition
High output*
I~'I DBG140BWB308
B
approx.O Low output*
C approx.5 Under any condition
* : Output voltage varies with camshaft rotation.
01-408-37
2. Disconnect the CMP sensor connector.
3. Inspect the following wiring harness for open or short circuit (continuity check).
• if there is an open or short circuit, repair or replace wiring harnesses.
,-------------------------------------,
CMPSENSOR
@!rJ
I~~I
DBG140BWB308
PCM
124 123 122 121 120 119 118 117 116 115 114 113 112 111 110 109 108 107 106 105 104 103 102 101
148 147 146 145 144 143 142 141 140 139 138 137 136 135 134 133 132 131 130 129 128 127 126 125
172 171 170 169 168 167 166 165 164 163 162 161 160 159 158 157 156 155 154 153 152 151 150 149
196 195 194 193 192 191 190 189 188 187 186 185 184 183 182 181 180 179 178 177 176 175 174 173
DBG113BWB319
Open circuit
• Power circuit (CMP sensor connector terminal C and PCM connector terminal 129)
• Signal circuit (CMP sensor connector terminal 8 and PCM connector terminal 160)
• Ground circuit (CMP sensor connector terminal A and PCM connector terminal 114)
Short circuit
• CMP sensor connector terminal A and PCM connector terminal 114 short to body ground
• CMP sensor connector terminal 8 and PCM connector terminal 160 short to power supply
• CMP sensor connector terminal 8 and PCM connector terminal 160 short to body ground
• CMP sensor connector terminal C and PCM connector terminal 129 short to power supply
CRANKSHAFT POSITION (CKP) SENSOR REMOVAL/INSTALLATION [WL-C, WE-C]

dcf014018220w03
Caution
• When foreign material, such as iron chips, gets on the CKP sensor, it can cause abnormal output
from the sensor because of flux turbulence and adversely affect engine control. Be sure there is
no foreign material on the CKP sensor when replacing.
• Do not forcefully pull the wiring harness of the CKP sensor. DOing so will break the wiring
harness.
01-408-38
2. Remove the under cover (AT).
3. Remove the insulator (AT).
1 CKP sensor installation bolt
2 CKP sensor (See 01-408-1 CKP Sensor Installation
Note.)
CKP Sensor Installation Note

1. Verify that there is no foreign material on the CKP sensor flange surface and the installation surface.
2. Verify that the O-ring is not damaged.
• If there is a damage, replace the CKP sensor.
3. Apply a small amount of clean oil to the O-ring and the head cover.
4. Press in the CKP sensor until the CMP sensor flange surface firmly adheres to the installation surface.
5. Verify that the O-ring is installed correctly to the sensor installation hole.
6. Tighten the bolt.
CRANKSHAFT POSITION (CKP) SENSOR INSPECTION [WL-C, WE-C]

dcf014018220w04
Note
• Before performing the following inspection, make sure to follow the procedure as indicated in the
troubleshooting flowchart.
Wave profile Inspection

1. Measure the wave profile between CKP sensor
connector terminal A-body ground, and CKP CKPSENSOR
wll
sensor connector terminal B-body ground. WIRING HARNESS-SIDE CONNECTOR
• If not within the specification, replace the CKP
sensor.
• If as specified, carry out the "Circuit Open!
Short Inspection".
I~~ I DBG140BWB310
Wave profile (Reference) I I I I I I [
1
I I I I I I I I 1 I
- -r - -,- -,- - - - T - - r - - r - -r - -.- - - -, - - T--
• 5 V/DIV (Y), 2 ms/DIV (X), DC range

I I I I I
--:- --:- + - -~+

--~ --~ --:- --:- - --,- -+--
Vehicle condition
:
-: -
I I
- - t - - T-
I I I I I I
+~l( '_
~ I - -: - - ~ - -
:t:' ',:t 1
I I I I I I I
_ _ _ J.. _' __ .J
ov
I I I I I I I I I [
r
--r--,--'-- --T--r-- --r--'--'--'--T--
I
I
I
[I
I I
I
I
I
I
I
I
I
I
I
I
I I
--.--'--1-- --T--r-- --,---.--,--'--7--

I I I I
I
r I
I r
I
I I
I
I
I I
--'---'---1-- --I--r-- --,---,---,--,--.--

I I I I I I I I 1 I
I I I I I I I I I I
DBG140AWB560
01-408-39
1. Disconnect the PCM connector. (See 01-40B-9 PCM REMOVAL/INSTALLATION [WL-C, WE-C].)
2. Inspect the following wiring harnesses for an open or short circuit. (Continuity check)
• if there is an open or short circuit, repair or replace wiring harnesses.
,------------------------------------,
CKP SENSOR
lEThl
I~~I
DBG140BWB310
PCM
124 123 122 121 120 119 118 117 116 115 114 113 112 111 110 109 108 107 106 105 104 103 102 101
148 147 146 145 144 143 142 141 140 139 138 137 136 135 134 133 132 131 130 129 128 127 126 125
172 171 170 169 168 167 166 165 164 163 162 161 160 159 158 157 156 155 154 153 152 151 150 149
196 195 194 193 192 191 190 189 188 187 186 185 184 183 182 181 180 179 178 177 176 175 174 173
DBG113BWB319
Open circuit
• Positive signal circuit (CKP sensor connector terminal A and PCM connector terminal 192)
• Negative signal circuit (CKP sensor connector terminal Band PCM connector terminal 193)
Short circuit
• CKP sensor connector terminal A and PCM connector terminal 192 short to power supply
• CKP sensor connector terminal A and PCM connector terminal 192 short to body ground
• CKP sensor connector terminal Band PCM connector terminal 193 short to power supply
• CKP sensor connector terminal Band PCM connector terminal 193 short to body ground
EGR VALVE POSITION SENSOR INSPECTION [WL-C, WE-C]

dcf014020300w02
Note
1. Disconnect the EGR valve connector.
2. Measure the resistance between EGR valve
connector terminals A and B.
W
EGR valve.
Short Inspection".
I~~I
Resistance
Approx. 5 kilohm
DBG140AWB557
01-408-40
Voltage Inspection
3. Measure the voltage between EGR valve connector terminal C and body ground.
• If not as specified, perform the "Circuit Open/short Inspection".
- If there is no open/short circuit replace the EGR valve. (See 01-168-4 EGR SYSTEM REMOVAU
Approx. 0.6 V
4. Start the engine and warm up the engine

completely. EGR VALVE POSITION SENSOR
WIRING HARNESS·SIDE CONNECTOR
@ibm
I~" I
DBG140BWB311
5. Measure the voltage between EGR valve

connector terminal C and body ground. EGR VALVE POSITION SENSOR
• If not as specified, perform the "Circuit Open/ WIRING HARNESS-SIDE CONNECTOR
Short inspection".
If there is no open/short circuit replace the
EGR valve. (See 01-168-4 EGR SYSTEM
REMOVAUINSTALLATION [WL-C, WE-
C].)
Above 3.0 V
DBG140BWB311
01-408-41
2. Disconnect the PCM connector. (See 01-40B-9 PCM REMOVAL/INSTALLATION [WL-C, WE-CD
• If there is an open or short circuit, repair or ,---------------------,
mI
I~~
DBG140BWB311
PCM
124 123. 122 121 120 119 118 117 116 115 114 113 112 111 110 109 108 107 106 105 104 103 102 101
148 147 146 145 144 143 142 141 140 139 138 137 136 135 134 133 132 131 130 129 128 127 126 125
172 171 170 169 168 167 166 165 164 163 162 161 160 159 158 157 156 155 154 153 152 151 150 149
196 195 194 193 192 191 190 189 188 187 186 185 184 183 182 181 180 179 178 177 176 175 174 173
DBG113BWB319
Open circuit
• Power circuit (EGR valve position sensor connector terminal Band PCM connector terminal 106)
• Signal circuit (EGR valve position sensor connector terminal C and PCM connector terminal 116)
• Ground circuit (EGR valve position sensor connector terminal A and PCM connector terminal 110)
Short circuit
• EGR valve position sensor connector terminal Band PCM connector terminal 106 short to ground
• EGR valve position sensor connector terminal C and PCM connector terminal 116 short to ground
CLUTCH PEDAL POSITION (CPP) SWITCH INSPECTION [WL-C, WE-C]

dcf014018660w02
Note
1. Disconnect the CPP switch connector.
2. Inspect for continuity between the CPP switch
terminals A and B using an ohmmeter.
• If not as specified, replace the CPP switch. CPPSWITCH
..
Short Inspection". ROD
Specification
Continuity
cpp switch Clutch pedal
condition PUSH
Push the rod Released No continuity
Except above Depressed Continuity
DBG140AWB328
01-408-42
• If there is an open or short circuit, repair or ,-----------------------,
CPPSWITCH
PCM
219 218 217 216 215 214 213 212 211 210 209 208 207
202 201
232 231 230 229 228 227 226 225 224 223 222 221 220
204 203
245 244 243 242 241 240 239 238 237 236 235 234 233
206 205
258 257 256 255 254 253 252 251 250 249 248 247 246
DBG113BWB318
Open circuit
• Power circuit (CPP switch connector terminal A and PCM connector terminal 228)
• Ground circuit (CPP switch connector terminal 8 and ground.)
Short circuit
• CPP switch connector terminal A and PCM connector terminal 228 short to ground.
NEUTRAL SWITCH INSPECTION [WL-C, WE-C]

dcf014017640w02
Note
1. Disconnect the neutral switch connector.
2. Inspect for continuity between the neutral switch terminals using an ohmmeter.
• If not as specified, replace the neutral switch.
• If as specified, carry out the "Circuit Open/Short Inspection".
,-----------------------,
Specification NEUTRAL SWITCH
Continuity
Neutral switch Shift lever
condition
Push the rod In neutral Continuity ROD
Except above Others No continuity
DBG140BWB312
01-408-43
• If there is an open or short circuit, repair or ,-----------------------,
t.
replace wiring harnesses. NEUTRAL SWITCH
DBG140BWB313
PCM
219 218 217 216 215 214 213 212 211 210 209 208 207
202 201
232 231 230 229 228 227 226 225 224 223 222 221 220
204 203
245 244 243 242 241 240 239 238 237 236 235 234 233
206 205
258 257 256 255 254 253 252 251 250 249 248 247 246
DBG113BWB318
Open circuit
• Power circuit (neutral switch connector terminal A and PCM connector terminal 240)
• Ground circuit (neutral switch terminal 8 and ground)
Short circuit
• Neutral switch connector terminal A and PCM connector terminal 240 short to ground
01-408-44
01-508 TECHNICAL DATA [WL-C, WE-C]

ENGINE TECHNICAL DATA
[WL-C, WE-C] .................... 01-508-1
ENGINE TECHNICAL DATA[WL-C, WE-C]

id0150b6800100
Item Specification
IN: 0.10-0.16 mm {0.0040-0.0062 in}
EX: 0.17-0.23 mm {0.0067-0.0090 in}
Standard: 2,942 {30, 427} [200]
Compression (kPa {kgf/cm 2, psi} [rpm]) Minimum: 2,648 {27, 384} [200]
Bolt head mark W
Bolt head mark N
Cylinder head bolt length Standard length: 113.2-113.8 mm {4.457-4.480 in}
Bolt head mark I
Standard length: 149-150 mm {5.867-5.905 in}
Pushing distance of the camshaft cap lower oil seal 0.0-0.4 mm {0.0-0.015 in}
Pushing distance of the front oil seal 0.0-0.4 mm {0.0-0.015 in}
Pushing distance of the rear oil seal 0.0-0.5 mm {0.0-0.019 in}
Oil pressure [2,500 rpm] 410-570 kPa {4.19-5.81 kgf/cm 2, 59.6-82.6 psi}
Oil capacity (approx. quantity) Oil and oil filter replacement: 7.0 {7.4 US qt, 6.2 Imp qt}
Front oil seal press-in amount 0.0-0.40 mm {0.O-O.015 in}
Fuel injection pump oil seal press-in amount 0.0-0.40 mm {0.0-0.015 in}
Standard oil pump tip clearance 0.10-0.19 mm {0.004D-0.0074 in}
Without heater: 8.8 L {9.3 US qt, 7.7 Imp qt}
Engine coolant capacity (approx. quantity)
With heater: 9.4 L {9.9 US qt, 8.3 Imp qt}
Cooling system cap valve opening pressure 93.2-122.6 kPa {0.95-1.25 kgf/cm2, 13.5-17.8 psi}
Initial-opening temperature and lift of the valve 80-84 °C {176-183 OF}
Full open temperature 95°C {203 OF}
Full open life 8.5 mm {0.33 in} or more
Battery electrolyte specific gravity [20°C {68 OF}] 1.22-1.29
65031 R (56): 165 A
75026R (52): 195 A
75026L (55): 195 A
95031 R (64): 250 A
65031 R (56): 4.0-5.0 A
75026R (52): 5.0-6.0 A
Battery slow charge current
75026L (55): 5.0-6.0 A
95031 R (64): 6.5-8.0 A
65031 R (56): 30 A
75026R (52): 35 A
Battery quick charge current [30 min.]
75026L (55): 35 A
95031 R (64): 40 A
Terminal B: B+
Generator standard voltage [Engine switch ON] Terminal L: Approx. 1 V
Terminal S: B+
01-508-1
Item Specification
Terminal 8: 14.1-14.7 V
Generator standard voltage [Idle, 20°C {68 OF}) Terminal L: 13.0-14.0 V
Generator rotor resistance (between slip rings) [20°C
2.3-2.7 ohms
{68 OF})
Standard: 4.8-6.0 N {0.49-0.61 kgf, 1.08-1.34Ibf}
Minimum: 2.16 N {0.22 kgf, 0.49 Ibf}
Starter no load test voltage 11 V
Starter no load test current 130 A or less
Starter pinion gap o mm {O in}
Starter armature runout 0.1 mm {0.039 in} max.
Standard: 26.7-36.1 N {2.73-3.68 kgf, 6.01-8.11 Ibf}
Minimum: 14.7 N {1.5 kgf, 3.3 Ibf}

(mm {in})
Drive Belt New' Used Limit
7.4-9.4 8.7-10.4
{0.30-0.37} {0.35-0.40}
6.1-6.9 7.1-8.0
a 11.3 {0.44} or more
{0.24-0.27} {0.28-0.31 }
AlC
10.0-11.0 11.3-12.6
b 17.4 {0.69} or more
{0.40-0.43} {0.45-0.49}
: A belt that has been on a running engine for less than five minutes.
Drive Belt Tension

(N {kgf, Ibf})
Drive Belt New' Used Limit
490-637 431-539
{50.0-64.9, 111-143} {44.0-54.9,96.9-121}
455-572 353-431
AlC 156 {15.9, 35.1} or less
{46.4-58.3,103-128} {36.0-43.9,79.4-96.8}
: A belt that has been on a running engine for less than five minutes.

Specification
Item
Europe Except Europe
API CF-4 or ACEA
Grade API CD/CE/CF-4 or ACEA 81/B3/85
81/83/85
Viscosity (SAE) 5W-30 5W-30, 10W-30, 10W-40
13.5 V, Engine hot
1,000 0-55 A
2,000 0-70 A
01-508-2
01-608 SERVICE TOOLS [WL-C, WE-C]

ENGINE SST[WL-C, WE-C] .......... 01-608-1
ENGINE SST[WL-C, WE-C]

1: Mazda SST number
Example
1:49 UN30 3050
2:303-050
Engine lifting
brackets
1:498011102A 1 :49 UN30 3050 1:49 L017 5AO

2:- 2:303-050 2:-
Crankshaft lock Engine lifting 8upport hanger

tool brackets
t
1:498010 1AO 1:498013102 1 :49 8010 301
2:- 2:- 2:-
Compression
gauge set
(Part of 498013
""
..
Adapter
(Part of 49 8013
1A1A)
Oil seal installer
1A1A)
e
1:49 F027 009 1:49 8010 001 1 :498011 103
2:- 2:- 2:-
Oil seal installer Oil seal installer Oil seal installer
n
1 :49 0187 280A 1:49 9200 146 1 :499200 147
2:- 2:- 2:-
Oil pressure Adapter A Adapter B

gauge (Part of 49 9200 (Part of 49 9200
145) 145)
1:49 9200 020A 1:498019005 1 :49 G030 797

2:- 2:- 2:-
~ ~
Belt tension Oil seal puller Handle
gauge (Part of 49 B025
OAO)
1:49 H033 101 1 :49 G028 208

2:- 2:-
Bearing
remover
Installer
(Part of 49
G0282A1)
0
01-608-1
SUSPENSION
GENERAL PROCEDURES ... 02-10 REAR SUSPENSION ........ 02-14

WHEEL ALIGNMENT ....... 02-11 TECHNICAL DATA .......... 02-50
WHEEL AND TIRES ........ 02-12 SERVICE TOOLS ........... 02-60
FRONT SUSPENSION ....... 02-13
02-10 GENERAL PROCEDURES

GENERAL PROCEDURES
(SUSPENSION) .................. 02-10-1
GENERAL PROCEDURES (SUSPENSION)

dcf02100000Ow01
Wheel And Tire Installation

1. When installing the wheels and tires, tighten the wheel nuts in a criss-cross pattern to the following tightening '-'!I.
torque. IiIiiiI
Tightening torque
88.2-117.6 N·m {9.00-11.99 kgf·m, 65.06-86.73 ft·lbf}
Suspension Links Removal/Installation

1. For the jOint sections with rubber bushings, raise the vehicle using a lift, and then temporarily tighten the
installatio!l bolts and nuts. Lower the vehicle to the ground and tighten them completely with the specified
torque.
(
Connector Disconnection
1. Disconnect the negative battery cable before performing any work that requires handling of connectors.
02-10-1
WHEEL ALIGNMENT
02-11 WHEEL ALIGNMENT

VEHICLE HEIGHT WHEEL ALIGNMENT
ADJUSTMENT [4x2] .............. 02-11-1 PRE-INSPECTION . ............... . 02-11-2
VEHICLE HEIGHT' FRONT WHEEL ALIGNMENT [4x2] .... 02-11-3
ADJUSTMENT [4x4] . .............. 02-11-2 FRONT WHEEL ALIGNMENT [4x4] .... 02-11-5
VEHICLE HEIGHT ADJUSTMENT [4x2]

dcf02110000Ow01
Caution
• If the vehicle height on a winch or towbar (bull bar or similar accessory) equipped vehicle is
adjusted, it is possible that the vehicle height will drop below specification again or the tires will
be subject to uneven wear. Without adjusting the vehicle height, adjust only the difference
between the left and right sides and perform a wheel alignmenUo specification.

2. Inspect the front and rear tire pressure and adjust it as necessary.
3. Measure the distance from the center of each ,.------.::....-----------------,
front wheel to the fender brim. yEASURIN: POINT
Standard vehicle height

Except Hi-Rider: 416-456 mm {16.4-17.9 A
SEC.
in}
A-A
Hi-Rider: 512-552 mm {20.2-21.7 in}
Left/right difference
10 mm {0.39 in} max.
Caution
AVF7412W005
• 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.
EXCEPT Hi-Rider Hi-Rider
DCF211ZWB001
5. Move the vehicle forward and back to seat each part.

6. Verify that the vehicle height is within the standard.
• If not, readjust the vehicle height.
02-11-1
WHEEL ALIGNMENT
VEHICLE HEIGHT ADJUSTMENT [4x4]
dcf02110000Ow02
Caution
• If the vehicle height on a winch or towbar (bullbar or similar accessory) equipped vehicle is
adjusted, it is possible that the vehicle height will drop below specification again or the tires will
be subject to uneven wear. Without adjusting the vehicle height, adjust only the difference
between the left and right sides and perform a wheel alignment to specification.

2. Inspect the front and rear tire pressure and adjust it as necessary.
3. Measure the distance from the center of each r-------------------,
front wheel to the fender brim. ySURINAG POINT
Standard vehicle height
Regular cab and Stretch cab (with Rear
Access System): 512-552 mm {20.2-21. 7 SEC. A
in} A-A
Double cab: 502-542 mm {19.8-21.3 in}
Left/right difference
10 mm {0.39 in} max.
Caution
AVF7412W005
• 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
• The vehicle height increases/decreases 3.3
mm {0.13 in} per anchor bolt rotation.
5. Move the vehicle forward and back to seat each

part.
6. Verify that the vehicle height is within the
standard.
AVF7412W004
• If not, readjust the vehicle height.
WHEEL ALIGNMENT PRE-INSPECTION

dcf02110000Ow03
1. Inspect the tire pressure.

• Adjust to the recommended pressure if necessary. (See 02-50-1 SUSPENSION TECHNICAL DATA.)
2. Inspect the wheel bearing play.
• Correct if necessary. (See 03-11-3 WHEEL HUB, STEERING KNUCKLE INSPECTION [4x2 (EXCEPT Hi-
Rider)].) (See 03-11-4 WHEEL HUB, STEERING KNUCKLE INSPECTION [Hi-Rider, 4x4].) (See 03-12-1
REAR AXLE INSPECTION.)
3. Inspect the wheel runout.
• Correct if necessary. (See 02-50-1 SUSPENSION TECHNICAL DATA.)
4. Inspect the ball joints and steering linkage for excessive looseness.
5. Park the vehicle on a level ground, in an unloaded condition*, and with the wheels straight forward.
Unloaded vehicle ..... Fuel tank is full. Engine coolant and engine oil are at specified level. Jack and tools are in
designated position.
02-11-2
WHEEL ALIGNMENT
6. Measure height H from the center of the wheel to FENDER BRIM
the fender brim. MEASUREMENT POINT
7. Verify that the difference between the left and
right dimension H is within the specification .
• If it exceeds the specification, repeat the Step
2-6.
H
Standard
10 mm {0.39 in} or less
CHU0211W001
FRONT WHEEL ALIGNMENT [4x2]

dcf02110000Ow04
Front wheel alignment [4x2] (Unloaded)

Specifications
Item Hi-Rider (Stretch
Hi-Rider (Double
Regular cab Double cab cab (with Rear
cab)
Access System)
Tire
Total toe-in [Tolerance (mm {in}) 5 {0.19}
±3 {0.12}]
Inner 33°00'-37°00' 31 °30'-35°30'
Maximum steering angle
Outer 30°00'-35°00' 27°00'-32°00'
Camber angle [Tolerance ±1 0] 0°35' 0°44' 0°45'
Caster angle [Tolerance ±1 0] 1°56' 1°54' 2°07' 2°06'
Steering axis inclination
8°25' 10°37' 10°35'
(reference value)
Note
• Unloaded vehicle: Fuel tank is full. Engine coolant and engine oil are at specified level. Jack and tools are
in designated position.
• Difference between the left and right dimension for camber is within 30'.
• Difference between the left and right dimension for caster is within 45'.
Maximum Steering Angle Adjustment

1. Loosen the adjusting bolt locknut.
2. Turn the adjusting bolt to provide the correct
turning angle.
Standard steering angle

Except Hi-Rider
Inner: 33°00'-37°00'
Outer: 30°00'-35°00'
Hi-Rider
Inner: 31 °30'-35°30'
Outer: 27°00'-32°00'
3. After adjustment, tighten the locknut to the

ADJUSTING BOL~
DBG0211ZWBOO
specified torque.
Tightening torque
39-59 N?m {4.0-S.0 kgf?m, 29-43 ft?lbf}
4. After adjusting the steering angle, always inspect and adjust the toe angle. (See 02-11-4 Total Toe-in
Adj ustment.)
02-11-3
WHEEL ALIGNMENT
Caster And Camber Adjustment
1. Loosen the upper arm shaft bolt and insert or
remove adjustment shims to provide the correct
angle.
No. Thickness (mm {in})
1 1.0 {0.039}
2 1.6 {0.063}
3 2.0 {0.079}
FRONT
4 3.2 {0.126}
5 4.0 {0.157} ~
6 0.6 {0.024}
7 1.0 {0.039}
8 1.6 {0.063}
9 2.0 {0.079}
10 3.2 {0.126}
11 4.0 {0.157}
Note
• Shims No.1-5 are used on either side. Do
not use more than two.
• Shims No.6-11 are used at the front and
rear of either sides. Do not use more than
one. AVF7412W003
• Camber (Shims No.1-5): A change of shim

thickness of 1 mm {0.039 in} results as follows:
Shim thickness Variation/1 mm {O.039 in}
Add Negative 15'
Reduce Positive 15'
• Caster (Shims No.6-11): A change of shim thickness (at front or rear only) of 1 mm {0.039 in} results as '(;
follows:
Shim
Variation/1 mm {O.039 in}
thickness
Add Increase 30'
Front side
Reduce Decrease 30'
Add Decrease 30'
Rear side
Reduce Increase 30'
2. After adjustment, tighten the upper arm shaft bolt to the specified torque.
Tightening torque
150-172 N·m {15.3-17.5 kgf·m, 111-126 ft·lbf}
Total Toe-in Adjustment

1. Loosen the locknut of the tie-rod end.
2. Turn the tie rods by the same amount in the opposite direction.
Total Toe-in Standard

2-8 mm {0.08-0.31 in}
Note
• One turn of the tie rod (both sides) changes the toe-in by about approx. 30 mm {1.18 in}.
• The left and right tie rods are both right threaded. To increase the toe-in, turn the right tie rod toward the
front of the vehicle and the left tie rod equally toward the rear.
02-11-4
WHEEL ALIGNMENT
3. Tighten the tie-rod end locknuts.
Tightening torque
68.6-78.5 N?m {7.00-8.00 kgf?m, 50.6-57.8
ft?lbf}
FRONT WHEEL ALIGNMENT [4x4]

dcf02110000Ow05

Specifications
Item Regular cab and Stretch cab
Double cab
(with Rear Access System)
Total toe-in jTire (mm {in}) 6 {0.23}
[Tolerance ±3 {0.12}]
Inner 31 °30'-35°30'
Outer 27°00'-32°00'
Camber angle (reference value) [Tolerance ±1°] 0°44' 0°45'
Caster angle (reference value) [Tolerance ±1 0] 2°07' 2°06'
Steering axis inclination (reference value) 10°37' 10°35'
Note
in deSignated position.
• Difference between the left and right dimension for camber is within 30'.
• Difference between the left and right dimension for caster is within 45'.
Maximum Steering Angle Adjustment

1. Remove the cap.
2. Loosen the adjusting bolt locknut.
3. Turn the adjusting bolt to provide the correct turning angle.
Standard steering angle

Inner: 31 °30'-35°30'
Outer: 27°00'-32°00'
4. After adjustment, tighten the locknut to the

specified torque.
Tightening torque
39-59 N?m {4.0-6.0 kgf?m, 29-43 ft?lbf}
5. Install the cap.
02-11-5
WHEEL ALIGNMENT
Caster and Camber Adjustment
1. Loosen the upper arm shaft bolt and insert or
remove adjustment shims to provide the correct
angle.
Adjusting shim
No. Thickness (mm (in})
1 1.0 {0.039}
2 1.6 {0.063}
3 2.0 {0.079} FRONT
4
5
3.2 {0.126}
4.0 {0.157}
\::J
6 0.6 {0.024}
7 1.0 {0.039}
8 1.6 {0.063}
9 2.0 {0.079}
10 3.2 {0.126}
11 4.0 {0.157}
Note
• Shims No.1-5 are used on either side. Do
not use more than two.
• Shims No.6-11 are used at the front and
rear of either sides. Do not use more than AVF7412W003
one.
• Camber (Shims No.1-5): A change of shim
thickness of 1 mm {0.039 in} results as follows:
Shim thickness Variation/1 mm {O.039 in}
Add Negative 15'
Reduce Positive 15'
• Caster (Shims No.6-11): A change of shim thickness (at front or rear only) of 1 mm {0.039 in} results as
follows:
Shim
thickness Variation/1 mm {O.039 in}
Add Increase 30'
Front side
Reduce Decrease 30'
Add Decrease 30'
Rear side
Reduce Increase 30'
2. After adjustment, tighten the upper arm shaft bolt to the specified torque.
Tightening torque
150-172 N·m {15.3-17.5 kgf.m, 111-126 ft.lbf}
3. Confirm the front wheel alignment as in the specification.

• If not within the specification, adjust the front wheel alignment again.
Total Toe-in Adjustment

1. Loosen the tie-rod end locknuts.
2. Turn the tie rods by the same amount in the opposite direction.
Total Toe-in Standard

3-9 mm {0.12-0.35 in}
Note
• One turn of the tie rod (both sides) changes the toe-in by about 30 mm {1.18 in}.
• The left and right tie rods are both right threaded, to increase the toe-in, turn the right tie rod toward the
front of the vehicle and the left tie rod equally toward the rear.
02-11-6
WHEEL ALIGNMENT
3. Tighten the tie-rod end locknuts.
Tightening torque
68.6-78.5 N·m {7.00-8.00 kgf.m, 50.6-57.8
ft.lbf}
02-11-7
WHEEL AND TIRES
02-12 WHEEL AND TIRES

WHEEL AND TIRE WHEEL AND TIRE
SPECiFiCATION ...•.•..••••.•.... 02-12-1 SPECIFICATION ..•.......•....•••• 02-12-1
WHEEL AND TIRE SPECIFICATION

id0212008001 b1
Wheel and tires

Item Specification
Size 15x61/2J 15x61/2J 16 x 7J
Offset (mm {in}) 20 {0.79} 25 {0.9S} 10 {0.39}
Wheel Pitch circle diameter (mm {in}) 139.7 {5.500}
Aluminum
Material Steel
I alloy
215170R15C 10611 04S
Steel Aluminum alloy
235175R 15 109S 245170R16111S

Size
Up to full
persons
Front 220 {(2.2), <32>} 210 {(2.1), <30>} 210 {(2.1), <30>}
Air pressure
Full load
Tire (kPa ((kgf/cm 2),
Up to full
<psi>}) 210 {(2.1), <30>} 210 {(2.1), <30>} 210 {(2.1), <30>}
Rear persons
Full load 375 {(3.S), <54>} 290 {(2.9), <42>} 270 {(2.7), <39>}
Remaining tread (mm {in}) 1.6 {0.06}
(N·m {kgf·m,
Lug nut tightening torque SS.2-117.6 {9.0Q-11.99, 65.06-S6.73}
ft·lbf})
Wheel Wheel and tire runout Radial direction 1.5 {0.06} max.
and tire
(mm {in}) Lateral direction 2.0 {O.OS} max.
Wheel imbalance*2 (g {oz}) 10 {0.35} max.
*1 : Total weight exceeds 120 9 {4.24 OZ}.

*2 : One balance weight: 60 9 {2.12 oz} max. If the total weight exceeds 120 9 {4.24 oz} on one side, rebalance
after moving the tire around on the rim. Do not use three or more balance weights.
WHEEL AND TIRE SPECIFICATION

id0212008001 b2
Wheel and tires

Item Specification
Size 15 x 6 1/2J 15x61/2J 16 x 7J
Offset (mm {in}) 20 {0.79} 25 {0.9S} 10 {0.39}
Aluminum
Material Steel Steel Aluminum alloy
Ialloy
Size 215170R15C 106/104S 235/75R 15 109S 245/70R16111S
No loaded
Air pressure Front 220 {(2.2), <32>} 210 {(2.1), <30>} 210 {(2.1), <30>}
Loaded
Tire (kPa {(kgf/cm 2),
No loaded 210 {(2.1), <30>} 210 {(2.1), <30>} 210 {(2.1), <30>}
<psi>}) Rear
Loaded 375 {(3.S), <54>} 290 {(2.9), <42>} 270 {(2.7), <39>}
(N·m {kgf·m,
Lug nut tightening torque SS.2-117.6 {9.00-11.99, 65.06-S6.73}
ft·lbf})
and tire
(mm {in}) Lateral direction 2.0 {O.OS} max.

02-12-1
FRONT SUSPENSION
02-13 FRONT SUSPENSION

FRONT SUSPENSION LOCATION TORSION BAR SPRING AND LOWER
INDEX [4x2 (EXCEPT Hi-Rider)] ..... 02-13-1 ARM REMOVAL/INSTALLATION
FRONT SUSPENSION LOCATION [Hi-Rider, 4x4] ................... . 02-13-9
INDEX [Hi-Rider] . ................. 02-13-2 FRONT LOWER ARM INSPECTION .... 02-13-13
FRONT SUSPENSION LOCATION FRONT UPPER ARM
INDEX [4x4] . ..................... 02-13-3 REMOVAL/INSTALLATION .......... 02-13-14
FRONT SHOCK ABSORBER FRONT UPPER ARM INSPECTION .... 02-13-16
REMOVAL/INSTALLATION . ......... 02-13-4 FRONT STABILIZER AND TENSION
FRONT SHOCK ABSORBER ROD REMOVAL/INSTALLATION
INSPECTION . .................... 02-13-4 [4x2 (EXCEPT Hi-Rider)] .......... . 02-13-16
FRONT SHOCK ABSORBER FRONT STABILIZER
DISPOSAL. . . . . . . . . . . . . . . . . . . . . . . 02-13-5 REMOVAL/INSTALLATION
TORSION BAR SPRING AND LOWER [Hi-Rider, 4x4] . .................. . 02-13-17
ARM REMOVAL/INSTALLATION
[4x2 (EXCEPT Hi-Rider)] . .......... 02-13-5
FRONT SUSPENSION LOCATION INDEX [4x2 (EXCEPT Hi-Rider)]

dcf02130000Ow01
DBG213ZWB028
1 Front shock absorber 3 Front upper arm

(See 02-13-4 FRONT SHOCK ABSORBER (See 02-13-14 FRONT UPPER ARM REMOVAU
REMOVAUINSTALLATION.) INSTALLATION.)
(See 02-13-4 FRONT SHOCK ABSORBER (See 02-13-16 FRONT UPPER ARM
INSPECTION.) INSPECTION.)
(See 02-13-5 FRONT SHOCK ABSORBER 4 Front stabilizer
DISPOSAL.) (See 02-13-16 FRONT STABILIZER AND TENSION
2 Torsion bar spring, lower arm ROD REMOVAUINSTALLATION [4x2 (EXCEPT Hi-
(See 02-13-5 TORSION BAR SPRING AND Rider)].)
LOWER ARM REMOVAUINSTALLATION [4x2
(EXCEPT Hi-Rider)].)
(See 02-13-13 FRONT LOWER ARM
INSPECTION.)
02-13-1
FRONT SUSPENSION
FRONT SUSPENSION LOCATION INDEX [Hi-Rider]

dcf021300000w02
DBG213ZWB029

DISPOSAL.) (See 02-13-17 FRONT STABILIZER REMOVAU
2 Torsion bar spring, lower arm INSTALLATION [Hi-Rider, 4x4].)
(See 02-13-9 TORSION BAR SPRING AND
LOWER ARM REMOVAUINSTALLATION [Hi-Rider,
4x4].)
INSPECTION.)
02-13-2
FRONT SUSPENSION
FRONT SUSPENSION LOCATION INDEX [4x4]
dcf021300000w03
L---------------------------------------------------------------------~D~BG~2~13~~~B==030
r!I1
DISPOSAL.) (See 02-13-17 FRONT STABILIZER REMOVAU
2 Torsion bar spring, lower arm INSTALLATION [Hi-Rider, 4x4].)
(See 02-13-9 TORSION BAR SPRING AND
LOWER ARM REMOVAUINSTALLATION [Hi-Rider,
4x4].)
INSPECTION.)
02-13-3
FRONT SUSPENSION
FRONT SHOCK ABSORBER REMOVAUINSTALLATION
dcf021334700w01

DBG0213ZWBOO
1 Nut 3 Bolt
(See 02-13-4 Nut Installation Note.) 4 Washer and nut
2 Retainer, bushing 5 Front shock absorber
Nut Installation Note

1. Tighten the nut so that the exposed thread of the
shock absorber piston is 6-8 mm {O.24-0.31
in}.
DBG0213ZWBOO
FRONT SHOCK ABSORBER INSPECTION

dcf021334700w02
1. Remove the front shock absorber.
2. Inspect for damage and oil leakage.
3. Compress and extend the shock absorber piston rod at least three times at a steady speed. From the fourth
compression stroke, verify that the operational force does not change and that there is no unusual noise.
• If there is any malfunction, replace the shock absorber.
02-13-4
FRONT SUSPENSION
FRONT SHOCK ABSORBER DffiPOSAL
dcf021334700w03
Warning
• Whenever drilling into a shock absorber, wear protective eye wear. The gas in the shock absorber
is pressurized, and could spray metal chips into the eyes and face when drilling.
1. Clamp a shock absorber on a flat surface or with the piston pointing downwards.
2. Drill a 2-3 mm {0.OS-0.12 in} hole at a point r-------------------....,
20-30 mm {0.S-1.2 in} from the bottom of the
tube, so that the gas can escape.
3. Turn the hole downwards.
4. The oil can be collected by moving the piston rod
several times up and down and cutting the tube at
the end.
5. Dispose of waste oil according to the waste
disposal law.
Note
• Shock absorber gas is nitrogen gas.
ABR7412W003
• Shock absorber oil is mineral oil.
TORSION BAR SPRING AND LOWER ARM REMOVAUINSTALLATION [4x2 (EXCEPT Hi-Rider)]
1. Remove the ASS sensor wiring harness brackets
dcf021334130w01 lim
installed to the upper arm and steering knuckle,
then move aside the ASS sensor.
4. Inspect the vehicle height and adjust it if
necessary. (See 02-11-1 VEHICLE HEIGHT
ADJUSTMENT [4x2].) 19-25
{2.0-2.5,
5. Inspect the front wheel alignment and adjust it if 15-18}
necessary. (See 02-11-3 FRONT WHEEL
ALIGNMENT [4x2].)
N'm {kgf.m, ft·lbf}
DBG213ZWB033
02-13-5
FRONT SUSPENSION
124-155
APPLY THREAD {12.7-15.8,
LOCKING COMPOUND 91.5-114}
VEHICLE
¢ FORWARD
DIRECTION
19 INSERT COTTER PIN

mJ FROM VEHICLE FORWARD
iii DIRECTION
DBG0213ZWBOO
1 Cotter pin 12 Lower arm spindle, washer, and nut

2 Nut 13 Rubber bushing
3 Front lower arm ball joint (See 02-13-7 Rubber Bushing Removal Note.)
(See 02-13-7 Front Lower Arm Ball Joint Removal (See 02-13-8 Rubber Bushing Installation Note.)
Note.) 14 Tension rod bolt
4 Shock absorber lower bolt and nut 15 Stabilizer bolt, bushing, retainer, spacer, and nut
5 Anchor bolt (See 02-13-8 Stabilizer Bolt, Bushing, Retainer,
(See 02-13-7 Anchor Bolt Removal Note.) Spacer, And Nut Installation Note.)
(See 02-13-9 Anchor Bolt Installation Note.) 16 Front lower arm
6 Anchor swivel 17 Bound stopper
7 Bolt and washer 18 Front lower arm ball joint
8 Torsion bar component 19 Clip
9 Anchor arm (See 02-13-8 Clip Installation Note.)
10 Torsion bar spring 20 Dust boot
(See 02-13-7 Torsion Bar Spring Removal Note.) 21 Clip
(See 02-13-8 Torsion Bar Spring Installation Note.) (See 02-13-8 Clip Installation Note.)
11 Torque plate 22 Dust boot
02-13-6
FRONT SUSPENSION
Front Lower Arm Ball Joint Removal Note
1. Separate the ball joint from the knuckle arm using
the SST.
DBG0213ZWBOO
Anchor Bolt Removal Note

1. Mark the anchor bolt and swivel for reference
during installation.
Torsion Bar Spring Removal Note

1. Mark the torsion bar spring, anchor arm, the
torsion bar spring and torque plate for reference
MATCHING MARK
DBG0213ZWBOO
Rubber Bushing Removal Note

1. Remove the rubber bushing from the body using
the SST.
DBG0213ZWBOO
02-13-7
FRONT SUSPENSION
Clip Installation Note
1. Install the SST to the ball joint stud with the stud
stands straight up.
2. Install the clip in the dust boot groove.
I:
DBG0213ZWBOO
Stabilizer Bolt, Bushing, Retainer, Spacer, And Nut Installation Note

1. Tighten the nuts so that 17.5-20.5 mm {0.689- .---,--------------:----,-",----,--r---:--/----:-/------,
0.807 in} of thread is exposed at the end of the /
bolt.
17.5-20.5 mm
{0.689-O.807 in}
DBG0213ZWBOO
Rubber Bushing Installation Note

1. Install a new bushing using the SST.
DBG0213ZWB01
--
Torsion Bar Spring Installation Note
1. Before installation, check the identification mark
on the end of the torsion bar spring.
® G)
OUTSIDE
~ OUT SIDE
OFTHE
VEHICLE
¢:J ©
L
©
R
¢OFTHE
VEHICLE
LEFT SIDE RIGHT SIDE
DBG213ZWB031
02-13-8
FRONT SUSPENSION
2. Align the marks made during removal, and
connect the torsion bar spring to the torque plate.
DBG0213ZWBOO
Anchor Bolt Installation Note

1. Install the anchor bolt, and tighten it until the
marks made during removal are aligned.
Note
• If the anchor bolt was not marked during
removal, install it as follows:
1. Lower the front suspension until the
upper arm contacts the rebound stopper.
2. Install the anchor arm so that the angle

A is 25°-34°.
DBG0213ZWB01
TORSION BAR SPRING AND LOWER ARM REMOVAL/INSTALLATION [Hi-Rider, 4x4]

dcf021334130w02
1. Remove the ASS sensor wiring harness brackets

19-25
2. Remove in the order indicated in the table. {2.0-2.5,
3. Install in the reverse order of removal. 19-25
15-18}
{2.0-2.5,
4. Inspect the vehicle height and adjust it as 15-18}
necessary. (See 02-11-2 VEHICLE HEIGHT
ADJUSTMENT [4x4].)
5. Inspect the front wheel alignment as necessary.
(See 02-11-5 FRONT WHEEL ALIGNMENT
[4x4].) N·m {kgf·m, ft.lbf}
DBG213ZWB034
02-13-9
FRONT SUSPENSION
124-155
{12.7-15.8,92-114}
9
APPLY THREAD
LOCKING COMPOUND
VEHICLE
¢ FORWARD
DIRECTION
lP~ INSERT COTTER PIN
muJ®
Ii)
FROM VEHICLE FORWARD
DIRECTION
70-93
{7.2-9.4,
52-58}
N·m {kgf·m, ft.lbf}
DBG0213ZWB01
1 Cotter pin 11 Torque plate

2 Nut 12 Lower arm spindle (rear), washer and nut
3 Front lower arm ball joint 13 Lower arm spindle (front), washer and nut
(See 02-13-7 Front Lower Arm Ball Joint Removal 14 Stabilizer bolt, bushing, retainer, spacer and nut
Note.) (See 02-13-8 Stabilizer Bolt, Bushing, Retainer,
4 Shock absorber lower bolt and nut Spacer, And Nut Installation Note.)
5 Anchor bolt 15 Front lower arm
(See 02-13-13 Anchor Bolt Installation Note.) 16 Bound stopper
6 Anchor swivel 17 Front lower arm ball joint
7 Bolt and washer 18 Clip
8 Torsion bar spring component (See 02-13-8 Clip Installation Note.)
9 Anchor arm 19 Dust boot
(See 02-13-11 Anchor Arm Removal Note.) 20 Front lower arm bushing
(See 02-13-12 Anchor Arm Installation Note.) (See 02-13-11 Front Lower Arm Bushing Removal
10 Torsion bar spring Note.)
(See 02-13-11 Torsion Bar Spring Removal Note.) (See 02-13-12 Front Lower Arm Bushing Installation
(See 02-13-12 Torsion Bar Spring Installation Note.) Note.)
02-13-10
FRONT SUSPENSION
Anchor Arm Removal Note
1. Mark the anchor arm and body for reference
DBG0213ZWB01
Torsion Bar Spring Removal Note

1. Mark the torsion bar spring and anchor arm, and
torsion bar spring and torque plate for reference
DBG0213ZWB01
Front Lower Arm Bushing Removal Note

1. Remove the front lower arm bushing using the
SST.
DBG0213ZWB01
02-13-11
FRONT SUSPENSION
Front Lower Arm Bushing Installation Note
1. Apply soapy water to the new bushing.
2. Install the bushing using the SST.
y.
DBG0213ZWB01
CD CD
Torsion Bar Spring Installation Note
1. Before installation, check the identification mark
on the end of the torsion bar spring.
OUT SIDE
OUTSIDE
OFTHE ¢:J © © ¢OFTHE
VEHICLE L R VEHICLE
LEFT SIDE RIGHT SIDE
DBG213ZWB031
2. Align the marks made during removal, and

connect the torsion bar spring to the torque plate.
~~ \ c'
JI)(
~
~ Y
DBG0213ZWB01
Anchor Arm Installation Note

1. Align the marks made during removal, and install
the anchor arm onto the torsion bar spring.
DBG0213ZWB01
02-13-12
FRONT SUSPENSION
Anchor Bolt Installation Note
1. Install the anchor bolt, and tighten it until the
marks made during removal are aligned.
Note
• If the anchor bolt was not marked during
removal, install it as follows:
1. Lower the front suspension until the
upper arm contacts the rebound stopper.
DBG0213ZWB01
2. Install the anchor arm so that the angle

A is 55°30'-64°30'.
DBG0213ZWB02
FRONT LOWER ARM INSPECTION

dcf021334130w03
1. Remove the front lower arm from the vehicle.
2. Inspect the front lower arm for bending or damage. If there is any malfunction, replace it.
3. Inspect the ball joint for excessive play. If there is any malfunction, replace the front lower arm.
4. Rotate the ball joint 5 times.
5. Measure the ball-joint rotational torque using the
SST and torque wrench.
Front lower arm ball joint rotational torque

[pull scale reading]
20-34 N {2.0-3.5 kgf, 4.4-7.7Ibf}
• If not within the specification, replace the front

lower arm.
DBG0213ZWB02
02-13-13
FRONT SUSPENSION
FRONT UPPER ARM REMOVAUINSTALLATION
dcf021334200w01
Caution
• Performing the following procedures without first removing the ABS wheel-speed sensor may
possibly cause an open circuit in the wiring harness if it is pulled by mistake. Before performing
the following procedures, remove the ABS wheel-speed sensor (axle side) and fix it to an
appropriate place where the sensor will not be pulled while servicing the vehicle.
1. Remove the ASS sensor wiring harness brackets 4x2 (EXCEPT Hi-Rider)
2. Remove in the order indicated in the table. 19-25
3. Install in the reverse order of removal. 19-25 {2.0-2.5,
4. Inspect the front wheel alignment and adjust it as {2.0-2.5, 15-18}
15-18}
necessary. (See 02-11-3 FRONT WH EEL
ALIGNMENT [4x2]) (See 02-11-5 FRONT
WHEEL ALIGNMENT [4x4].)
Hi-Rider, 4x4
19-25
19-25 {2.0-2.5,
{2.0-2.5, 15-18}
15-18} ~-_;A/

DCF213ZWBOOl
VEHICLE
¢FORWARD
DIRECTION
INSERT COTTER PIN FROM

VEHICLE FORWARD DIRECTION
DBG213ZWB032
1 Brake hose bracket 4 Bolt and washer

2 Cotter pin and nut (See 02-13-15 Bolt and Washer Installation Note.)
3 Front upper arm ball joint 5 Adjustment shim
(See 02-13-15 Front Upper Arm Ball Joint Removal (See 02-13-15 Adjustment Shim Removal Note.)
Note.) 6 Front upper arm component
7 Bolt and washer
02-13-14
FRONT SUSPENSION
8 IFront upper arm ball joint 9 Clip

(See 02-13-15 Clip Installation Note.)
10 Dust boot
Front Upper Arm Ball Joint Removal Note

1. Separate the upper arm ball joint from the knuckle
arm using the SST.
DBG0213ZWB02
Adjustment Shim Removal Note

1. Note the number, amount and position of the shims so that they are reinstalled in the correct positions.
Clip Installation Note

1. Install the SST to the ball joint stud with the stud stands straight up.
P.'!'
IiiiiI
2. Install the clip in the dust boot groove using the ,-----------------------,
SST.
A' I A I'
DBG0213ZWB02
Bolt and Washer Installation Note
Note
• Be sure to use a pre-set torque wrench to precisely tighten the upper arm shaft.
1. Install the bolt and washer, and tighten the bolt to

the specified torque.
Tightening torque
150-172 N·m {15.3-17.5 kgf·m, 111-126
ft·lbf}
02-13-15
FRONT SUSPENSION
FRONT UPPER ARM INSPECTION
dcf021334200w02
1. Remove the front upper arm from the vehicle.

2. Inspect the front upper arm for bending or damage. If there is any malfunction, replace it.
3. Inspect the ball joint for excessive play, and if there is any malfunction, replace the front upper arm.
5. Measure the ball-joint rotational torque using the
I:
SST and pull scale.
Front upper arm ball joint rotational torque

[pull scale reading]
4.9-25 N {O.5-2.5 kgf, 1.1-5.5Ibf}
• If not within the specification, replace the front

upper arm.
DBG0213ZWB02
FRONT STABILIZER AND TENSION ROD REMOVAUINSTALLATION [4x2 (EXCEPT Hi-Rider)]

dcf021334100w01

24.5-36.2
{2.50-3.69,
18.1-26.6}
e
~94-116
{9.5-13.0,
§ {9.5-11.9,
69-86}
69-94}

DBG0213ZWB02
1 Nut 6 Stabilizer bushing

(See 02-13-8 Stabilizer Bolt, Bushing, Retainer, 7 Front stabilizer
Spacer, And Nut Installation Note.)
8 Tension rod nut
2 Retainer (See 02-13-17 Tension Rod Nut Installation Note.)
3 Bolt 9 Bushing and retainer
4 Bushing, retainer and spacer 10 Tension rod
5 Stabilizer bracket
02-13-16
FRONT SUSPENSION
Tension Rod Nut I
1. Tighten the t ~stallation Note
enslon
98 .5 mm {3.88 in}. r0 d nuts so that length L is
DBG0213ZWB02
FRONT STABILIZER REMO

1. Remove in the . VAL/INSTALLATION [ . . dcf021334100w02
2. Install in the order Indicated in th HI-Rlder,4x41
___ .:...::.~r
,everse order of removal.
e table.
Retainer and b . DBG0213ZWB02

Nut 5 R ushlng
(See 02-13-8 Stablhzer
..
Spacer A
Reta. ' nd Nut Installation'N~:h)1n9,
Bolt B .
Retainer,
etainer, bushin g, and ssprua;-;c::;;e:;:-r- - - - - -
-::6:-1f-:S':":ta=b=T'"
I Izer bracket
Bolt mer and bush.
mg e.------ I Stabilizer bushing
Front stabilizer
02-13-17
REAR SUSPENSION
02-14 REAR SUSPENSION

REAR SUSPENSION REAR SHOCK ABSORBER
LOCATION INDEX ................. 02-14-1 INSPECTION . ................... . 02-14-4
REAR SHOCK ABSORBER AND LEAF REAR SHOCK ABSORBER
SPRING REMOVAUINSTALLATION DISPOSAL. ..................... . 02-14-4
[4x2 (EXCEPT Hi-Rider)] . .......... 02-14-2 REAR STABILIZER REMOVAU
REAR SHOCK ABSORBER AND LEAF INSTALLATION [WL-C, WE-C] ...... . 02-14-5
SPRING REMOVAUINSTALLATION
[Hi-Rider, 4x4] ................... 02-14-3
REAR SUSPENSION LOCATION INDEX

dcf02140000Ow01
Hi-Rider, 4x4
DCF214ZWB001
Leaf spring 2 Rear shock absorber

(See 02-14-2 REAR SHOCK ABSORBER AND (See 02-14-4 REAR SHOCK ABSORBER
LEAF SPRING REMOVAUINSTALLATION [4x2 INSPECTION.)
(EXCEPT Hi-Rider)].) (See 02-14-4 REAR SHOCK ABSORBER
(See 02-14-3 REAR SHOCK ABSORBER AND DISPOSAL.)
LEAF SPRING REMOVAUINSTALLATION [Hi- 3 Rear stabilizer (WL-C and WE-C)
Rider, 4x4].) (See 02-14-5 REAR STABILIZER REMOVAU
02-14-1
REAR SUSPENSION
REAR SHOCK ABSORBER AND LEAF SPRING REMOVAL/INSTALLATION [4x2 (EXCEPT Hi-Rider)]
dcf021405910w01
Warning .
• Use safety stands for support of the left and right axle casings, and while supporting the
differential casing with a jack, raise or lower the jack as necessary.
1. Support the frame with safety stands and place a jack under the differential casing.
4. After installation, tighten the bolt (leaf spring front side) completely on the ground.
59-78 {G.O-8.0, 44-57}
78-98
...
-!i!
III
{8.0-10.0, 58-72}
DBG214ZWB001
1 Nut and washer 8 Shackle pin

2 Rear shock absorber 9 Shackle plate
3 Nut 10 Leaf spring component
4 U-bolt 11 Leaf spring bushing
5 Spring clamp (See 02-14~3 Leaf Spring Bushing Removal Note.)
(See 02-14-3 Leaf Spring Bushing Installation
6 Stopper rubber
Note.)
7 Bolt
02 .. 14-2
REAR SUSPENSION
Leaf Spring Bushing Removal Note
1. Secure the leaf spring in a vise and remove the
bushing using a chisel.
AVF7416W004
Leaf Spring Bushing Installation Note

1. Press in the bushing using a suitable pipe.
DBG214ZWB100
REAR SHOCK ABSORBER AND LEAF SPRING REMOVAUINSTALLATION [Hi-Rider, 4x4]

dcf021405910w02
Warning
• Use safety stands for support of the left and right axle casings, and while supporting the
differential casing with a jack, raise or lower the jack as necessary.
1. Support the frame with safety stands and place a jack under the differential casing.
4. After installation, tighten the bolt (leaf spring front side) completely on the ground.
02-14-3
REAR SUSPENSION
APPLY THREAD
LOCKING COMP~ ~'-'-~1'5'
4W
~.H'"
~~
I 59-78 {6.1-7.9, 44-57} -
DBG214ZWB006
1 Bolt, washer and nut 9 Bolt

2 Nut, washer, and retainer 10 Shackle pin
3 Shock absorber 11 Shackle plate
4 Nut and washer 12 Leaf spring component
5 U-bolt 13 Leaf spring bushing
6 Set plate (See 02-14-3 Leaf Spring Bushing Removal Note.)
(See 02-14-3 Leaf Spring Bushing Installation
7 Spring clamp Note.)
8 Bound stopper
REAR SHOCK ABSORBER INSPECTION

dcf021428700w01
1. Inspect the rear shock absorber in the same way as the front shock absorber.
(See 02-13-4 FRONT SHOCK ABSORBER INSPECTION.)
REAR SHOCK ABSORBER DISPOSAL

dcf021428700w02
1. Dispose the rear shock absorber in the same way as the front shock absorber. (See 02-13-5 FRONT SHOCK
ABSORBER DISPOSAL.)
02.-14-4
REAR SUSPENSION
REAR STABILIZER REMOVAL/INSTALLATION [WL-C, WE-C]
dcf02142810OW01

3. After installation, tighten the control link installation bolt completely on the ground.
<G
J~
~ 36-54
{3.7-5.5,
27-39}
~[)) ~~
:::::::=~~::::===:::::/
36-45
'-..,. ~{3.7-4.5,
~~ 27-33}
DBG214ZWB003
1 Rear stabilizer component 3 Stabilizer bracket

(See 02-14-6 Rear Stabilizer Component 4 Bushing
Installation Note.) (See 02-14-5 Bushing Installation Note.)
2 Stabilizer control link 5 Rear stabilizer
(See 02-14-6 Stabilizer Control Link Installation
Note.)
Bushing Installation Note

1. Install the bushings aligned with the painting part. FRONT
~===:::- t
BUSHING
DBG214ZWB004
02-14-5
REAR SUSPENSION
Stabilizer Control Link Installation Note
1. Install the stabilizer control link with the painted area pointing towards the under side and inside of the vehicle.
Rear Stabilizer Component Installation Note

1. Temporarily install the rear stabilizer component.
2. Tighten the stabilizer control link nut.
3. Tighten the stabilizer bracket nut.
02-14-6
TECHNICAL DATA

SUSPENSION TECHNICAL DATA . .... 02-50-1
SUSPENSION TECHNICAL DATA

dcf02500000Ow01
Specifications .
Item Hi-Rider (Stretch
Hi-Rider (Double
Regular cab Double cab cab (with Rear
cab)
Access System)
Tire
Total toe-in [Tolerance (mm {in}) 5 {0.19}
±3 {0.12})
Inner 33°00/-37°00/ 31 °30/-35°30/
Outer 30°00/-35°00/ 27°00/-32°00/
Camber angle [Tolerance ±1 0] 0°35/ 0°44/ 0°45/
Caster angle [Tolerance ±1 0] 1°56/ 1°54/ 2°07' 2°06/
Steering axis inclination 8°25/ 10°35/
10°37'
(reference value)
Note
• Difference between the left and right dimension for camber is within 30/.
• Difference between the left and right dimension for caster is within 45/.

Specifications
Item Stretch cab
Double cab
(with Rear Access System)
Total toe-in ITire (mm {in}) 6 {0.23}
[Tolerance ±3 {0.12}]
Inner 31 °30/-35°30/
Outer 27°00/-32°00/
Camber angle (reference value) [Tolerance ±1°] 0°44/ 0°45/
Caster angle (reference value) [Tolerance ±1 0] 2°07' 2°06/
Steering axis inclination (reference value) 10°37' 10°35/
Note
• Difference between the left and right dimension for camber is within 30/.
• Difference between the left and right dimension for caster is within 45/.
02-50-1
TECHNICAL DATA
Wheel and tires [Australian Specs.]
Item Specification
Size 15x61/2J 15x61/2J 16 x 7J
Offset (mm {in}) 20 {0.79} 25 {0.98} 10 {0.39}
Aluminum
Material Steel Steel Aluminum alloy
I alloy
Size 215/70R15C 106/1048 235/75R 15 109S 245/70R16 111 S
Up to full
Front persons 220 {(2.2), <32>} 210 {(2.1), <30>} 210 {(2.1), <30>}
Air pressure
Full load
Tire (kPa ((kgf/cm 2),
Up to full
<psi>}) 210 {(2.1), <30>} 210 {(2.1), <30>} 210 {(2.1), <30>}
Rear persons
Full load 375 {(3.8), <54>} 290 {(2.9), <42>} 270 {(2.7), <39>}
(N?m {kgf?m
Lug nut tightening torque 88.2-117.6 {9.00-11.99, 65.06-86.73}
ft?lbf})
and tire
(mm {in}) Lateral direction 2.0 {0.08} max.

Suspension
Item Specification
Front lower arm ball joint rotational torque [pull scale
20-34 N {2.0-3.5 kgf, 4.4-7.7Ibf}
reading]
Front upper arm ball joint rotational torque [pull scale
4.9-25 N {0.5-2.5 kgf, 1.1-5.5 Ibf}
reading]
02-50-2
SERVICE TOOLS
02-60 SERVICE TOOLS

SUSPENSiON ..................... 02-60-1
SUSPENSION
dcf026000000w01
49 T028 3AO 49 0180 510B 49 U0342AO
Ball joint puller Preload Lower arm

set measuring bushing puller &
attachment installer set
49 UB39 615
Bushing puller&
installer set
49 U034208
U 49 U034 209
CHpgu;de U
r.4~9~G~03~2~3~4~1----------------r-----------------------+---------------------~1!!J
Oil seal installer
02-60-1
DRIVELINE/AXLE
ON-BOARD DIAGNOSTIC .... 03-02 DRIVE SHAFT.............. 03-13

SYMPTOM DIFFERENTIAL [FRONT] ..... 03-14A
TROUBLESHOOTING DIFFERENTIAL [REAR] ...... 03-14B
[LSD (LIMITED SLIP PROPELLER SHAFT ........ 03-15
DIFFERENTIAL)] .......... 03-03 TRANSFER ................ 03-16
GENERAL PROCEDURES ... 03-10 4-WHEEL DRIVE ........... 03-18
FRONT AXLE .............. 03-11 TECHNICAL DATA .......... 03-50
REAR AXLE ............... 03-12 SERVICE TOOLS ........... 03-60

RFW (REMOTE FREEWHEEL) DTC P1814 ........................ 03-02-6
SYSTEM WIRING DIAGRAM ...••... 03-02-1 DTC P1815 ........................ 03-02-8
RFW (REMOTE FREEWHEEL) DTC P1878 ........................ 03-02-10
ON-BOARD DIAGNOSiS ...••..•..• 03-02-1 DTC P1879 ........................ 03-02-11
DTC P1812 ........... , ........... 03-02-2 DTC P1880 ........................ 03-02-12
DTC P1813 ....................... 03-02-4 DTC P1885 ........................ 03-02-14
RFW (REMOTE FREEWHEEL) SYSTEM WIRING DIAGRAM

dcf03022710Ow01
MAIN RELAY
ENGINE
SWITCH
RFW FREE
SOLENOID
T 4x4 INDICATOR
BATTERY : LIGHT
PCM (RFW CONTROL)

RFW INDICATOR
LIGHT
DBG302ZWB003
RFW (REMOTE FREEWHEEL) ON-BOARD DIAGNOSIS

dcf03022710Ow02
• The on-board diagnostic procedures are mentioned in Section 01. (See 01-028-6 FOREWORD [WL-C, WE-
C].)
03-02-1
ON-BOARD DIAGNOSTIC
DTCTable
DTC Diagnosis system component Page
P1812 RFW Lock solenoid valve circuit failure (See 03-02-2 OTC P1812.)
P1813 RFW Lock solenoid valve open circuit (See 03-02-4 OTC P1813.)
P1814 RFW Lock solenoid valve circuit/short to battery (See 03-02-6 OTC P1814.)
P1815 RFW Lock solenoid valve circuit/short to ground (See 03-02-8 OTC P1815.)
P1878 RFW Free solenoid valve circuit failure (See 03-02-10 OTC P1878.)
P1879 RFW Free solenoid valve open circuit (See 03-02-11 OTC P1879.)
P1880 RFW Free solenoid valve circuit/short to battery (See 03-02-12 OTC P1880.)
P1885 RFW Free solenoid valve circuit/short to ground (See 03-02-14 OTC P1885.)
Simulation Item Table

Command name Output part Operation Operating condition
4WOMOOE_L 4x4 indicator light
HUBLOCK RFW Lock solenoid valve
On/Off Engine switch at ON
HUBLOCK_L RFW Free solenoid valve
NTFLAMP RFW indicator light
DTC P1812
dcf030227100w03
DTC P1812 RFW Lock solenoid valve circuit failure

DETECTION
• Circuit malfunction has been detected in the Lock solenoid valve.
CONDITION
POSSIBLE • Lock solenoid valve malfunction
B~--------------------~
BATTERY
PCM
PCM MAIN RELAY WIRING RFW LOCK SOLENOID VALVE

WIRING HARNESS-SIDE CONNECTOR HARNESS-SIDE CONNECTOR WIRING HARNESS-SIDE
CONNECTOR
rciAl
254 253 CETIJ
03-02-2
ON-BOARD DIAGNOSTIC
1 INSPECT LOCK SOLENOID VALVE Yes Replace the Lock solenoid valve, then go to the next step.
• Remove the Lock solenoid valve.
• Inspect the Lock solenoid valve.
(See 03-18-4 LOCK AND FREE SOLENOID
VALVES INSPECTION.)
• Shift the transfer select lever.
03-02-3
ON-BOARD DIAGNOSTIC
DTC P1813
dcf030227100w04
DTC P1813 RFW Lock solenoid valve open circuit

DETECTION
• Open circuit has been detected in the Lock solenoid valve wiring harness.
CONDITION
• Lock solenoid valve malfunction
POSSIBLE • Open circuit in wiring harness between Lock solenoid valve terminal A and main relay
CAUSE • Open circuit in wiring harness between Lock solenoid valve terminal Band PCM terminal 253
• Short to ground in wiring harness between Lock solenoid valve terminal Band PCM terminal 253
• PCM malfunction
BATTERY
T
I
I
PCM

CONNECTOR
rciAl
CilTI
1 INSPECT LOCK SOLENOID VALVE Yes Repair or replace the terminal, then go to Step 6.
• Disconnect the Lock solenoid valve connector.
03-02-4
ON-BOARD DIAGNOSTIC
INSPECT LOCK SOLENOID VALVE CIRCUIT

FOR OPEN CIRCUIT Repair or replace the wiring harness for a possible open
circuits:
- Lock solenoid valve terminal A (wiring
harness-side) and main relay terminal D
- Lock solenoid valve terminal B (wiring
harness-side)
4 INSPECT LOCK SOLENOID VALVE CIRCUIT Yes or replace the wiring harness for a possible short to
FOR SHORT TO GROUND , then go to Step 6.
circuits:
- Lock solenoid valve terminal A (wiring
5 INSPECT LOCK SOLENOID VALVE
• Inspect the Lock solenoid valve.
VALVES INSPECTION.)
• Is the same DTC nro,,,ont'}
(See01-02B-10AFTER REPAIR No Troubleshooting completed.
• Are DTCs present?
03-02-5
ON-BOARD DIAGNOSTIC
DTC P1814
dcf03022710OW05
DTC P1814 RFW Lock solenoid valve circuit/short to battery

DETECTION
• Short to power circuit has been detected in the Lock solenoid valve wiring harness.
CONDITION
CAUSE • Short to power supply in wiring harness between Lock solenoid valve terminal Band PCM terminal 253
• PCM malfunction
BATTERY
PCM

CONNECTOR
rciAl
~
03-02-6
ON-BOARD DIAGNOSTIC

3 INSPECT LOCK SOLENOID VALVE CIRCUIT Yes Repair or replace the wiring harness for short to power
SHORT TO POWER SUPPLY supply, then go to the Step 5.
(Engine off).
circuits:
• Inspect the Lock solenoid valve. No Go to the next step.
VALVES INSPECTION.)
• Make sure to reconnect all disconnected WE-C).)
II
03-02-7
ON-BOARD DIAGNOSTIC
DTC P1815
dcf030227100w06
DTC P1815 RFW Lock solenoid valve circuit/short to ground

DETECTION
• Short to ground circuit has been detected in the Lock solenoid valve wiring harness.
CONDITION
POSSIBLE • Open circuit in wiring harness between Lock solenoid valve terminal A and main relay
CAUSE • Open circuit in wiring harness between Lock solenoid valve terminal Band PCM terminal 253
• Short to ground in wiring harness between Lock solenoid valve terminal Band PCM terminal 253
• PCM malfunction
Br------------------------.
D~----_.----------~
BATTERY
T
I
I
PCM

CONNECTOR
rciAl
219
254 253 ~
03-02-8
ON-BOARD DIAGNOSTIC

3 INSPECT LOCK SOLENOID VALVE POWER Yes Go to the next step.
SUPPLY CIRCUIT FOR OPEN CIRCUIT No Repair or replace the wiring harness for open, then go to
• Turn the engine switch to the ON position Step 7.
(Engine off).
• Measure the voltage between Lock solenoid
body ground.
4 INSPECT LOCK SOLENOID VALVE CIRCUIT Yes Repair or replace the wiring harness for a possible short to
• Inspect for continuity between Lock solenoid
body ground.
5 INSPECT LOCK SOLENOID VALVE CIRCUIT Yes Go to the next step.
circuits:
harness-side)
• Inspect the Lock solenoid valve. No Go to the next step.
VALVES INSPECTION.)
03-02-9
ON-BOARD DIAGNOSTIC
DTC P1878
dcf030227100w07
DTC P1878 RFW Free solenoid valve circuit failure

DETECTION
• Circuit malfunction has been detected in the Free solenoid valve.
CONDITION
POSSIBLE • Free solenoid valve malfunction
BATTERY
T RFW FREE
SOLENOID
VALVE
PCM
PCM MAIN RELAY WIRING RFW FREE SOLENOID VALVE

CONNECTOR
rc1Al
ITTIJ
1 INSPECT FREE SOLENOID VALVE Yes Replace the Free solenoid valve, then go to the next step.
• Remove the Free solenoid valve.
• Inspect the Free solenoid valve.
VALVES INSPECTION.)
• Perform the "After Repair Procedure". (See 01-02B-11 DTC TABLE [WL-C, WE-CJ.)
PROCEDURE [WL-C, WE-CJ.)
03-02-10
ON-BOARD DIAGNOSTIC
DTC P1879
dcfD3D2271 DOwDS
• Open circuit has been detected in the Free solenoid valve wiring harness.
• Free solenoid valve malfunction

POSSIBLE • Open circuit in wiring harness between Free solenoid valve terminal A and main relay
CAUSE • Open circuit in wiring harness between Free solenoid valve terminal Band PCM terminal 254
• Short to ground in wiring harness between Free solenoid valve terminal Band PCM terminal 254
• PCM malfunction
BATTERY
T RFW FREE
SOLENOID
VALVE
PCM

CONNECTOR
rc1Al
[BTI
1 INSPECT FREE SOLENOID VALVE Yes Repair or replace the terminal, then go to Step 6.
• Disconnect the Free solenoid valve connector.
03-02-11
ON-BOARD DIAGNOSTIC

3 INSPECT FREE SOLENOID VALVE CIRCUIT Yes Go to the next step.
circuits:
- Free solenoid valve terminal A (wiring
harness-side) and main relay terminal D
- Free solenoid valve terminal B (wiring
harness-side)
4 INSPECT FREE SOLENOID VALVE CIRCUIT Yes Repair or replace the wiring harness for a possible short to
circuits:
- Free solenoid valve terminal A (wiring
• Inspect the Free solenoid valve. No Go to the next step.
VALVES INSPECTION.)
• Perform the "After Repair Procedure". (See 01-02B-11 DTC TABLE [WL -C, WE-C].)
DTC P1880
dcf030227100w09
DTC P1880 RFW Free solenoid valve circuit/short to battery

DETECTION
CONDITION • Short to power circuit has been detected in the Free solenoid valve wiring harness.

CAUSE • Short to power supply in wiring harness between Free solenoid valve terminal Band PCM terminal 254
• PCM malfunction
03-02-12
ON-BOARD DIAGNOSTIC
DTC P1880 RFW Free solenoid valve circuiUshort to battery
BATTERY
T RFW FREE
SOLENOID
VALVE
PCM

CONNECTOR
rc1Al
~
pulled~out pins, and corrosion).
3 INSPECT FREE SOLENOID VALVE CIRCUIT Yes Repair or replace the wiring harness for short to power
SHORT TO POWER SUPPLY supply, then go to the Step 5.
(Engine off).
circuits:
03-02-13
ON-BOARD DIAGNOSTIC

VALVES INSPECTION.)
WE-C].)
DTe P1885
dcf0302271 OOw1 0
DTC P1885 RFW Free solenoid valve circuiUshort to ground

DETECTION
CONDITION • Short to ground circuit has been detected in the Free solenoid valve wiring harness.

POSSIBLE • Open circuit in wiring harness between Free solenoid valve terminal A and main relay
CAUSE • Open circuit in wiring harness between Free solenoid valve terminal Band PCM terminal 254
• Short to GND in wiring harness between Free solenoid valve terminal Band PCM terminal 254
• PCM malfunction
03-02-14
ON-BOARD DIAGNOSTIC
BATIERY
T RFW FREE
I
I
SOLENOID
VALVE
PCM

CONNECTOR
rciAl
254 253 CilTI
3 INSPECT FREE SOLENOID VALVE POWER Yes Go to the next step.
SUPPLY CIRCUIT FOR OPEN CIRCUIT No Repair or replace the wiring harness for open, then go to
• Turn the engine switch to the ON position Step 7.
(Engine off).
• Measure the voltage between Free solenoid
body ground.
03-02-15
ON-BOARD DIAGNOSTIC

4 INSPECT FREE SOLENOID VALVE CIRCUIT Yes Repair or replace the wiring harness for a possible short to
• Inspect for continuity between Free solenoid
valve terminal 8 (wiring harness-side) and
body ground.
5 INSPECT FREE SOLENOID VALVE CIRCUIT Yes Go to the next step.
circuits:
- Free solenoid valve terminal 8 (wiring
harness-side)
VALVES INSPECTION.)
03-02-16
ON-BOARD DIAGNOSTIC [4x4 control module]
03-02 ON-BOARD DIAGNOSTIC [4x4 control module]

4x4 CONTROL SYSTEM WIRING DIAGRAM DTe No.3 [4x4 control module] ....... 03-02-6
[4x4 control module] .............. 03-02:-2 DTe No.4 [4x4 control module] ....... 03-02-8
4x4 CONTROL SYSTEM ON-BOARD DTe No.5 [4x4 control module] ....... 03-02-9
DIAGNOSIS [4x4 control module] .... 03-02-2 DTe No.6 [4x4 control module] ....... 03-02-11
DTC No.1 [4x4 control module] ....... 03-02-4 DTe No.7 [4x4 control module] ....... 03-02-12
DTC No.2 [4x4 control module] ....... 03-02-5
03-02-1
4x4 CONTROL SYSTEM WIRING DIAGRAM [4x4 control module]
id0302a1801500
4x4
CONTROL
B+ IG1
MODULE
TRANSFER CASE
CLUTCH COIL
TCM
DLC
4x4 SWITCH
4x2 HI
A
4x4 HI
D
4x4LO
C
DIGITAL TR SENSOR J ] - - - - - (
FREE SOLENOID
arnffw00001937
4x4 CONTROL SYSTEM ON-BOARD DlAGNOSIS[4x4 control module]

id0302a1801600
Reading DTC procedure

1. Turn the engine switch off.
2. Connect an inspection lamp to the DLC terminal
FAT and battery.
(Engine off)
4. The inspection lamp will indicate a DTC by
flashing.
Note
• A verified DTC is flashed 3 times repeatedly
by the inspection lamp.
• If more than one DTC is detected, the first
DTC is displayed, and then next one is
displayed.
5. Repair the malfunctioning part using the verified

BATTERY
DTC.
6. After completion of repairs, clear all DTCs from
memory. arnffwOOOO 1958
03-02-2
Clearing DTC procedure
1. Turn the engine switch off.
2. Attach a jumper wire to the DLC terminal FAT and
ground. JUMPER
3. Turn the engine switch to the ON position. WIRE
(Engine off)
4. Turn the engine switch off after 5 s or more has
FAT
ili
elapsed.
5. Remove the jumper wire.
6. Verify that the same DTC is not present.
BODY GROUND
DTCTable
DTC
Inspection lamp flashing pattern Possible cause Page
No.
4x4 control module (See OTC No.1 [4x4
~
~GINE SWITCH ON, DEFECTIVE CODE ,~
~
'5sec. malfunction control module].)
0.6 sec. 1 sec.! _ _ _ _ _----l .-ON

. - '-OFF
3 sec. 0.5 sec. 3 sec.
2 Motor component (See OTC No.2 [4x4
~
ENGINESWITCHON,~DEFECTIVECODE '~
(shift motor) control module].)
0.5 sec.
0.6 sec. 1 sec. 0.5 sec. malfunction
'-ON
I...-_ _ _ _----l '-OFF
3 sec. 0.5 sec. 0.5 sec. 3 sec.
3
'I Clutch coil (See OTC NO.3 [4x4
~
.ENGINESWITCHON,~~CODE
r
malfunction control module].)
0.6 sec. 1 sec. 1 sec. '-ON
--------1 '-OFF
3 sec. 0.5 sec. 0.5 sec. 3 sec.
4 Speed sensor (See OTC No.4 [4x4
~
ENGINE SWITCH ON, ~DEFECTIVE CODE '~
0.5 sec.
0.6 sec. 1 sec. .-ON
I...-_ _ _ _----J .-OFF
3 sec. 3 sec.
0.5 sec.
5 Solenoid valve (See OTC NO.5 [4x4
~
ENGINESWITCHON'~DEFECTIVECODE .~
0.6 sec. 1 sec. 0.5 sec. 1 sec.
.-ON
1...-------1 '-OFF
3 sec. 3 sec.
0.5 sec.
6 ENGINE SWITCH ON DEFECTIVE CODE 4x4 switch (See OTC No.6 [4x4
I_~~se_c_._ _ _ _~~ ~ °fl~ec_'_ _ _ _----l~:~~F

3 sec. ' ~. 3 sec.
0.5 sec.
7 I,ENGINE SWITCH O~ I DEFECTIVE CODE Motor component (See OTC NO.7 [4x4
(position sensor) control module].)
1 sec. 1 sec. malfunction
3 sec.
0.5 sec.
03-02-3
DTC No.1 [4x4 control module]
id0302a1801700
DTC No.1 4x4 CM malfunction

DETECTION
• Open circuit or short to ground has been detected in the 4x4 CM wiring harness.
CONDITION
• Open circuit or short to ground in the wiring harness between the following 4x4 CM terminals T, Y, Z and
battery
POSSIBLE
• Open circuit in the wiring harness between the following 4x4 CM terminals W, X and ground
CAUSE
• 4x4 CM malfunction
• Poor connection at connector (female terminal)
ENGINE SWITCH
--v'
- .-- -
- - -
BATTERY
r-r-
1-':-
I
-
I
'-- t-
®Q9 \:!) (6) CD
4x4CM
7.7- 7i7-
4x4CM
_0 n 1 ~
M
cc=l
K I G
n
E C
II
A
Y W U S Q 0
Z X V T R P N L J H F 0 B
I~~ I
1 MEASURE VOLTAGE BETWEEN 4x4 CONTROL Yes Go to the next step.
MODULE CONNECTOR TERMINAL T, Y, Z AND No Repair or replace the wiring harness, then go to step 3.
GROUND
• Turn engine switch ON.
• Is the voltage greater than 10 V?
2 INSPECT FOR CONTINUITY BETWEEN 4x4 Yes Go to the next step.
CONTROL MODULE CONNECTOR TERMINAL No Repair or replace the wiring harness, then go to next step.
W, X AND GROUND
• Turn engine switch OFF.
3 VERIFY THAT THE SAME DTC IS NOT Yes If the malfunction recurs, replace the 4x4 CM, then go to
PRESENT the next step.
• Clear the DTCs from the memory. (See 03-18-5 4x4 CONTROL MODULE REMOVAU
(See 03-02-2 4x4 CONTROL SYSTEM ON- INSTALLATION [AT (5R55S)].)
BOARD DIAGNOSIS[4x4 control module].) No Go to the next step.
2 VERIFY THAT NO OTHER DTCS ARE PRESENT Yes Go to the applicable DTC troubleshooting.
• Are any DTCs present? (See 03-02-2 4x4 CONTROL SYSTEM ON-BOARD
DIAGNOSIS[4x4 control module].)
No Troubleshooting completed.
03-02-4
id0302a1801800
DTC No.2 Motor component (shift motor) malfunction

DETECTION
• Open circuit or short to ground has been detected in the motor component (shift motor) wiring harness.
CONDITION
• Open circuit or short to ground in the wiring harness between the following 4x4 CM terminals and the motor
component (shift motor) terminals:
- 4x4 CM terminal A- motor component (shift motor) terminal C
POSSIBLE - 4x4 CM terminal B- motor component (shift motor) terminal C
CAUSE - 4x4 CM terminal C- motor component (shift motor) terminal F
- 4x4 CM terminal D- motor component (shift motor) terminal F
• Motor component (shift motor) malfunction
4x4 CM TRANSFER CASE
MOTOR COMPONENT
4x4CM MOTOR COMPONENT

n n r ~;:=r 1 n n
y W U S Q 0 M K I G E C A
1 INSPECT MOTOR COMPONENT (SHIFT Yes Go to the next step.
MOTOR) No Replace the motor component, then go to step 4.
• Inspect the motor component (shift motor).
(See 03-16-4 MOTOR INSPECTION [5R55S].)
• Is the motor component (shift motor)?
2 INSPECT MOTOR COMPONENT (SHIFT Yes Repair or replace the wiring harness, then go to Step 4.
MOTOR) WIRING HARNESS FOR SHORT TO No Go to the next step.
GROUND
• Disconnect the 4x4 CM connector.
• Disconnect the motor component connector.
• Inspect for continuity between the motor
component connector terminals A, B, C, D
(vehicle harness-side) and body ground.
03-02-5

3 INSPECT MOTOR COMPONENT (SHIFT Yes Go to the next step.
MOTOR) WIRING HARNESS FOR OPEN No Repair or replace the wiring harness, then go to next step.
CIRCUIT
• Inspect for continuity between the 4x4 CM
connector (vehicle harness-side) and the
following vehicle harness-side terminals of
motor component:
- 4x4 CM connector A- Motor component
(shift motor) terminal C
- 4x4 CM connector B- Motor component
(shift motor) terminal C
- 4x4 CM connector C- Motor component
(shift motor) terminal F
- 4x4 CM connector D- Motor component
(shift motor) terminal F
4 VERIFY THAT THE SAME DTC IS NOT Yes Repeat the inspection from Step 1.
PRESENT If the malfunction recurs, replace the 4x4 CM, then go to
• Reconnect all disconnected connectors. the next step.
• Clear the DTCs from the memory. (See 03-18-S 4x4 CONTROL MODULE REMOVAU
(See 03-02-2 4x4 CONTROL SYSTEM ON- INSTALLATION [AT (SRSSS)].)
• Change the current transfer mode by operating
the 4x4 switch.(2H-4H-4L)
S VERIFY THAT NO OTHER DTCS ARE PRESENT Yes Go to the applicable DTC troubleshooting.

id0302a1801900
DTC No.3 Clutch coil malfunction

DETECTION
• Open circuit, short to ground or short to battery has been detected in the clutch coil wiring harness.
CONDITION
• Open circuit in the wiring harness between 4x4CM terminal U and clutch coil terminal C, short to battery or
POSSIBLE to ground
CAUSE • Clutch coil malfunction
4x4CM TRANSFER CASE
r
cg: ~
P
V CLUTCH COIL
4x4CM SPEED SENSOR

fl n ~ =r 1 n n L....I
y U Q 0 M K I G E C A
~I I I In
W S
C B A
I~~ I I~~I
03-02-6
1 INSPECT CLUTCH COIL Yes Go to the next step.
• Turn the engine switch off. No Replace the clutch coil, then go to step 5.
• Inspect the clutch coil.
(See 03-16-6 CLUTCH COIL INSPECTION
[5R55S].)
• Is the clutch coil normal?
2 INSPECT CLUTCH COIL WIRING HARNESS Yes Repair or replace the wiring harness, then go to step 5.
FOR SHORT TO GROUND No Go to the next step.
• Disconnect the clutch coil connector.
connector terminal U (vehicle harness-side)
and body ground.
3 INSPECT CLUTCH COIL WIRING HARNESS Yes Go to the next step.
FOR SHORT TO POWER SUPPLY CIRCUIT No Repair or replace the wiring harness, then go to step 5.
• Measure voltage between the clutch coil
connector terminal C (vehicle harness-side)
and body ground.
• Is the voltage 1 V or less?
4 INSPECT CLUTCH COIL WIRING HARNESS Yes Go to the next step.
FOR OPEN CIRCUIT No Repair or replace the wiring harness, then go to step 5.
connector U (vehicle harness-side) and the
vehicle harness-side terminal C of clutch coil.
5 VERIFY THAT THE SAME DTC IS NOT Yes Repeat the inspection from step 1.
(See 03-18-5 4x4 CONTROL MODULE REMOVALJ
• Clear the DTCs from the memory.
the 4x4 switch.(2H-4H)
03-02-7
id0302a 1802000
DTC No.4 Speed sensor malfunction

DETECTION
• Open circuit or short to ground has been detected in the speed sensor wiring harness.
CONDITION
• Open circuit or short to ground in the wiring harness between the following 4x4 CM terminals and the
speed sensor terminals:
POSSIBLE - 4x4 CM terminal M- speed sensor terminal B
CAUSE - 4x4 CM terminal N- speed sensor terminal A
• Speed sensor malfunction
4x4CM TRANSFER CASE
I
4x4CM
~ I~ ~~~~~R II
SPEED SENSOR
r n lEt rrl n rl
~I:I
Y W U S Q 0 M K I G E C A
A
z X V T R P N L J H F 0 B ID
I~~ I I~~I
1 INSPECT SPEED SENSOR Yes Go to the next step.
• Turn the engine switch off. No Replace the speed sensor, then go to step 4.
• Inspect the speed sensor. (See 03-16-4 SPEED SENSOR REMOVAUINSTALLATION
(See 03-16-3 SPEED SENSOR INSPECTION [5R55S].)
[5R55S].)
• Is the speed sensor normal?
2 INSPECT SPEED SENSOR WIRING HARNESS Yes Repair or replace the wiring harness, then go to step 4.
• Disconnect the speed sensor connector.
connector terminals M, N (vehicle harness-
3 INSPECT SPEED SENSOR WIRING HARNESS Yes Go to the next step.
FOR OPEN CIRCUIT No Repair or replace the wiring harness, then go to next step.
speed sensor:
- 4x4 CM connector M- speed sensor
terminal B
- 4x4 CM connector N- speed sensor
terminal A
(See 03-18-5 4x4 CONTROL MODULE REMOVAU
• Clear the DTCs from the memory. INSTALLATION [AT (5R55S)].)
(See 03-02-2 4x4 CONTROL SYSTEM ON-
03-02-8


id0302a1802100
DTC No.5 Solenoid valve malfunction

DETECTION
• Open circuit or short to ground has been detected in the solenoid valve wiring harness.
CONDITION
• Open circuit or short to ground in the wiring harness between the 4x4 CM terminal V and the lock solenoid
valve terminal B
• Open circuit or short to ground in the wiring harness between the 4x4 CM terminal V and the 4x4 relay
terminal E
• Open circuit or short to ground in the wiring harness between the free solenoid valve terminal B and the
POSSIBLE
4x4 relay terminal B
CAUSE
• Open circuit in the wiring harness between the lock solenoid valve terminal A and ground
• Open circuit in the wiring harness between the 4x4 relay terminal A, D and ground
• Open circuit in the wiring harness between the free solenoid valve terminal A and battery
• lock solenoid malfunction
LOCK SOLENOID 4x4CM
ENGINE SWITCH
BATTERY
FREE SOLENOID
4x4CM 4x4 RELAY WIRING LOCK AND FREE SOLENOID

WIRING HARNESS-SIDE CONNECTOR HARNESS-SIDE VALVES WIRING HARNESS-SIDE
CONNECTOR CONNECTOR
n n r 1=L? 1 _n n
~ IA
Y W U S Q 0 M K I G E C A
LE 1 I
1 INSPECT SOLENOID VALVE WIRING HARNESS Yes Repair or replace the wiring harness, then go to step 6.
• Disconnect the lock solenoid connector.
• Disconnect the 4x4 relay connector.
connector terminal V (vehicle harness-side)
and body ground.
• Inspect for continuity between the 4x4 relay
connector terminal B (vehicle harness-side)
and body ground.
03-02-9

2 INSPECT SOLENOID VALVE WIRING HARNESS Yes Go to the next step.
FOR OPEN CIRCUIT No Repair or replace the wiring harness, then go to step 6.
and the vehicle harness-side terminal B of lock
solenoid.
and the vehicle harness-side terminal E of 4x4
relay.
• Inspect for continuity between the lock solenoid
connector terminal A (vehicle harness-side)
and body ground.
• Inspect for continuity between the 4x4 relay
connector terminals A, D (vehicle harness-
• Inspect for continuity between the free solenoid
connector terminal B (vehicle harness-side)
and the vehicle harness-side terminal B of 4x4
relay.
3 MEASURE VOLTAGE BETWEEN FREE Yes Go to the next step.
SOLENOID VALVE CONNECTOR TERMINAL A No Repair or replace the wiring harness, then go to step 6.
AND GROUND
4 INSPECT SOLENOID VALVE Yes Go to the next step.
• Inspect the lock and free solenoid valves. No Replace the solenoid valve, then go to the step 6.
• Is the lock and free solenoid valves normal?
5 INSPECT 4x4 RELAY Yes Go to the next step.
• Inspect the 4x4 relay. No Replace the 4x4 relay, then go to the next step.
• Is the 4x4 relay normal?
(See 03-18-5 4x4 CONTROL MODULE REMOVAU
• Clear the DTCs from the memory. INSTALLATION [AT (5R55S)].)
(See 03-02-2 4x4 CONTROL SYSTEM ON-
the 4x4 switch.(2H-4H)
03-02-10
id0302a1802200
DTC No.6 4x4 switch malfunction

DETECTION
• Open circuit or short to ground has been detected in the 4x4 switch wiring harness.
CONDITION
• Open circuit or short to ground in the wiring harness between the following 4x4 CM terminals and the 4x4
switch terminals:
POSSIBLE - 4x4 CM terminal G- 4x4 switch terminal A
CAUSE - 4x4 CM terminal F- 4x4 switch terminal C
• 4x4 switch malfunction
4x4CM 4x4SWITCH
G l I - - - - - - - { A 4x2 HI
F~-----~ }-~~o
F}-------'
4x4CM 4x4SWITCH
r n r-a==t ;=r 1 n n E C A
Z X V T R P N L J H F D B F D B
1 INSPECT 4x4 SWITCH Yes Go to the next step.
• Turn the engine switch ott. No Replace the 4x4 switch, then go to step 4.
• Inspect the 4x4 switch. (See 03-18-3 4x4 SWITCH REMOVAUINSTALLATION [AT
(See 03-18-2 4x4 SWITCH INSPECTION [AT (5R55S)].)
(5R55S)].)
• Is the 4x4 switch normal?
2 INSPECT 4x4 SWITCH WIRING HARNESS FOR Yes Repair or replace the wiring harness, then go to step 4.
SHORT TO GROUND No Go to the next step.
• Disconnect the 4x4 switch connector.
connector terminals G, F (vehicle harness-
3 INSPECT 4x4 SWITCH WIRING HARNESS FOR Yes Go to the next step.
OPEN CIRCUIT No Repair or replace the wiring harness, then go to step 4.
following vehicle harness-side terminals of 4x4
switch:
- 4x4 CM connector G- 4x4 switch terminal
A
- 4x4 CM connector F- 4x4 switch terminal
C
03-02-11

• Clear the DTCs from the memory. (See 03-18-3 4x4 SWITCH REMOVAUINSTALLATION [AT
(See 03-02-2 4x4 CONTROL SYSTEM ON- (SRSSS)].)
S VERIFY THAT NO OTHER DTCS ARE PRESENT Yes Go to the applicable DTC troubleshooting.
OTC No.7 [4x4 control module]

id0302a 1802300
DTC No.2 Motor component (position sensor) malfunction

DETECTION • Open circuit or short to ground has been detected in the motor component (position sensor) wiring
CONDITION harness.
• Open circuit or short to ground in the wiring harness between the following 4x4 CM terminals and the motor
component (position sensor) terminals:
- 4x4 CM terminal N- motor component (position sensor) terminal G
- 4x4 CM terminal J- motor component (position sensor) terminal E
POSSIBLE
- 4x4 CM terminal 1- motor component (position sensor) terminal B
CAUSE
- 4x4 CM terminal L- motor component (position sensor) terminal A
- 4x4 eM terminal H- motor component (position sensor) terminal D
• Motor component (position sensor) malfunction
4x4 CM TRANSFER CASE
MOTOR COMPONENT
POSITION 4
4x4CM MOTOR COMPONENT

n n r"E::L =r 1 n n
03-02-12
1 INSPECT MOTOR COMP(jNENT (POSITION Yes Go to the next step.
SENSOR) No Replace the motor component, then go to the next step.
• Turn the engine switch off. (See 03-16-5 MOTOR REMOVAUINSTALLATION
• Inspect the Motor component (position sensor) [5R55S].)
(See 03-16-4 MOTOR INSPECTION [5R55S].)
• Is the Motor component (position sensor)
normal?
2 INSPECT MOTOR COMPONENT (POSITION Yes Repair or replace the wiring harness, then go to step 4.
SENSOR) FOR SHORT TO GROUND No Go to the next step.
• Disconnect the motor component connector.
• Inspect for continuity between the motor
component connector terminals N, J, I, L, H
(vehicle harness-side) and body ground.
3 INSPECT MOTOR COMPONENT (POSITION Yes Go to the next step.
SENSOR) WIRING HARNESS FOR OPEN No Repair or replace the wiring harness, then go to step 4.
CIRCUIT
motor component:
- 4x4 CM connector N- Motor component
terminal G
- 4x4 CM connector J- Motor component
terminal E
- 4x4 CM connector 1- Motor component
terminal B
- 4x4 CM connector L- Motor component
terminal A
- 4x4 CM connector H- Motor component
terminal D
• Clear the DTCs from the memory. (See 03-18-5 4x4 CONTROL MODULE REMOVAU
03-02-13
SYMPTOM TROUBLESHOOTING [LSD (LIMITED SLIP DIFFERENTIAL)]
03-03 SYMPTOM TROUBLESHOOTING [LSD (LIMITED

SLIP DIFFERENTIAL)]
FOREWORD ...................... 03-03-1 NO.2 NO RFW OPERATION FROM
PRECAUTION . .................... 03-03-2 LOCK TO FREE (RFW INDICATOR
SYMPTOM TROUBLESHOOTING . .... 03-03-2 LIGHT DOES NOT GO OFF) ........ . 03-03-5
NO.1 NO RFW OPERATION FROM NO.3 NOISE . ..................... . 03-03-7
FREE TO LOCK (RFW INDICATOR NO.4 OIL LEAKAGE . ............... . 03-03-8
LIGHT DOES NOT ILLUMINATE) .... 03-03-3
FOREWORD
dcf03032710Ow01
Malfunction vehicle delivered
Questionnaire Confirm all customer problems using a questionnaire.
Verify malfunction symptoms Confirm malfunction on actual vehicle.
I Symptom troubleshooting [ ~ OTC inspection [Inspect for OTCs using current diagnostic tool.
Perform applicable troubleshooting inspection according to

diagnostic index.
Verify that malfunctions have been repaired
Troubleshooting completed
DCF303ZWBOOl
03-03-1
PRECAUTION
dcf030327100w02
• This section only mentions unique symptoms of the trouble caused by RFW. Inspect and repair if necessary for
trouble caused by other sources.
• Inspect the connector and terminal connections when inspecting the wiring harness. (The cause of the
malfunction may be a poor connection in the connectors, terminals, or wiring harness.)
. Quick Diagnosis Chart
x: Applicable
Possible factor
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Troubleshooting item
LL
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1 No RFW operation from free to lock

X X X X X X X X X X X X X X
2 No RFW operation from lock to free

X X X X X X X X X X X X X X
3 Noise
X X X X
4 Oil leakage
X X
DBG303ZWB001
. SYMPTOM TROUBLESHOOTING
dcf03032710OW03
• Verify the symptoms, and perform troubleshooting according to the appropriate number.
No. Symptom Description
1 • Free solenoid valve malfunction
• RFW indicator light bulb malfunction
• RFW actuator malfunction
• RFW switch malfunction
• Print plate in instrument cluster malfunction
• Main fuse malfunction
No RFW operation from free to lock (RFW • Transfer neutral switch malfunction
indicator light does not illuminate.) • 4x4 indicator switch malfunction
• peM malfunction
• RFW control box malfunction
• Air leakage from vacuum hose
• One-way check valve malfunction
• Related fusses and/or harness malfunction
03-03-2

2 • Lock solenoid valve malfunction
• Main fuse malfunction
• RFW main switch malfunction
No RFW operation from lock to free (RFW • Transfer neutral switch malfunction
indicator light does not go off.) • 4x4 indicator switch malfunction
• PCM malfunction
• Related fuses and/or harness malfunction
3 • Joint shaft bearing abrasion or damage
Noise • RFW hub abrasion
• Joint shaft abrasion
4 Oil leakage • RFW control box is poorly installed
NO.1 NO RFW OPERATION FROM FREE TO LOCK (RFW INDICATOR LIGHT DOES NOT ILLUMINATE)
dcf030327100w04
1 NO RFW OPERATION FROM FREE TO LOCK (RFW INDICATOR LIGHT DOES NOT ILLUMINATE.)
DESCRIPTION RFW does not change from free to lock.
• Transfer neutral switch malfunction
• 4x4 indicator switch malfunction
• PCM malfunction
• RFW indicator light bulb malfunction
• Main fuse and/or main relay malfunction
• Related fuses and/or harnesses malfunction
1 INSPECT MAIN FUSE. Yes Go to next step.
• Is it OK? No Replace main fuse, then go to Step 27.
2 INSPECT RFW INDICATOR LIGHT BULB Yes Go to next step.
• Is it OK? No Replace the RFW indicator light bulb, then go to Step 27.
3 MEASURE VOLTAGE BETWEEN Yes Go to next step.
INSTRUMENT CLUSTER CONNECTOR No ' Repair wiring harness between main fuse and instrument
TERMINAL 1 F AND GROUND. cluster, then go to Step 27.
4 MEASURE VOLTAGE BETWEEN Yes Repair wiring harness between instrument cluster and PCM,
INSTRUMENT CLUSTER CONNECTOR then go to Step 27.
TERMINAL 1 D AND GROUND. No Replace print plate in instrument cluster, then go to Step 27.
5 MEASURE VOLTAGE BETWEEN FREE Yes Connect free solenoid valve, then go to next step.
SOLENOID VALVE CONNECTOR TERMINAL No Repair wiring harness between main relay and free solenoid
A AND GROUND. valve connector, then go to Step 27.
• Disconnect free solenoid valve connector.
• measure voltage between free solenoid
valve connector terminal A and ground.
03-03-3

6 MEASURE VOLTAGE BETWEEN FREE Yes Go to next step.
SOLENOID VALVE CONNECTOR TERMINAL No Inspect free solenoid valve, then go to Step 27.
B AND GROUND.
7 MEASURE VOLTAGE BETWEEN PCM Yes Go to next step.
CONNECTOR TERMINAL 254 AND GROUND. No Repair'wiring harness between free solenoid valve and
• Is the voltage greater than 10 V? PCM, then go to Step 27.
8 MEASURE VOLTAGE BETWEEN LOCK Yes Connect lock solenoid valve, then go to next step.
SOLENOID VALVE CONNECTOR TERMINAL No Repair wiring harness between main relay and lock solenoid
• Disconnect lock solenoid valve connector.
9 MEASURE VOLTAGE BETWEEN LOCK Yes Go to next step.
SOLENOID VALVE CONNECTOR TERMINAL No Repair wiring harness between PCM and ground, then go to
B AND GROUND. Step 27.
CONNECTOR TERMINAL 253 AND GROUND. No Inspect lock solenoid valve, then go to Step 27.
11 INSPECT FOR CONTINUITY BETWEEN PCM Yes Go to next step.
CONNECTOR TERMINAL 202/204/206 AND No Repair wiring harness between PCM and ground, then go to
GROUND. Step 27.
12 INSPECT FOR CONTINUITY BETWEEN PCM Yes Go to Step 16.
CONNECTOR TERMINAL 135 AND GROUND. No Go to next step.
13 INSPECT FOR CONTINUITY BETWEEN Yes Repair wiring harness between PCM and transfer neutral
TRANSFER NEUTRAL SWITCH CONNECTOR switch, then go to Step 27.
TERMINAL A AND GROUND. No Go to next step.
14 INSPECT TRANSFER NEUTRAL SWITCH. Yes Go to next step.
• Is it OK? No Replace transfer neutral switch, then go to Step 27.
15 INSPECT FOR CONTINUITY BETWEEN Yes Go to next step.
TRANSFER NEUTRAL SWITCH CONNECTOR No Repair wiring harness between transfer neutral switch and
TERMINAL B AND GROUND. ground, then go to Step 27.
• Shift select lever to 4x4 indicator position.
17 INSPECT FOR CONTINUITY BETWEEN 4X4 Yes Repair wiring harness between 4x4 indicator switch and
INDICATOR SWITCH CONNECTOR PCM, then go to Step 27.
18 INSPECT 4X4 INDICATOR SWITCH. Yes Go to next step.
• Is it OK? No Replace 4x4 indicator switch, then go to Step 27.
19 INSPECT FOR CONTINUITY BETWEEN 4X4 Yes Go to next step.
INDICATOR SWITCH CONNECTOR No Repair wiring harness between 4x4 indicator switch and
• Shift select lever to 4H position.
21 INSPECT FOR CONTINUITY BETWEEN RFW Yes Repair wiring harness between PCM and RFW switch, then
SWITCH CONNECTOR TERMINAL A AND go to Step 27.
GROUND. No Go to next step.
03-03-4

22 INSPECT RFW SWITCH. Yes Go to next step.
• Is it OK? No Replace RFW switch, then go to Step 27.
23 INSPECT FOR CONTINUITY BETWEEN RFW Yes Go to next step.
SWITCH CONNECTOR TERMINAL BAND No Repair wiring harness between RFW switch and ground,
GROUND. then go to Step 27.
24 INSPECT ONE-WAY CHECK VALVE. Yes Go to next step.
• Is it OK? No Replace one-way check valve, then go to Step 27.
25 INSPECT RFW CONTROL BOX. Yes Go to next step.
• Is it OK? No Replace RFW control box, then go to Step 27.
26 INSPECT VACUUM IN VACUUM HOSES. Yes Go to next step.
• Is it OK? No Replace vacuum in vacuum hoses, then go to Step 27.
27 DOES RFW OPERATE FROM FREE TO Yes Troubleshooting completed. Explain repairs to customer.
LOCK? No Inspect malfunction symptoms again, then repeat from Step
• Turn engine switch ON. 1 if malfunction occurs again.
• Shift select lever from 2H to 4H position.
• Does RFW operate from free to lock?
NO.2 NO RFW OPERATION FROM LOCK TO FREE (RFW INDICATOR LIGHT DOES NOT GO OFF)
dcf030327100wOS
2 NO RFW OPERATION FROM LOCK TO FREE (RFW INDICATOR LIGHT DOES NOT GO OFF.)
DESCRIPTION RFW does not change from lock to free.
• RFW main switch malfunction
• Transfer neutral switch malfunction
• 4x4 indicator switch malfunction
• PCM malfunction
• Air leakage from vacuum reservoir or actuator system
• One-way check valve
1 INSPECT FOR CONTINUITY BETWEEN Yes Repair wiring harness between PCM and instrument cluster,
INSTRUMENT CLUSTER TERMINAL 1 F AND then go to Step 30.
GROUND. No Inspect for no continuity between instrument cluster terminal
• Disconnect instrument cluster connector 1F and ground
NO.1.
2 INSPECT MAIN RELAY. Yes Repair wiring harness between main relay and PCM, then
• Inspect main relay. go to Step 29.
• Is it OK? No Replace the main relay, then go to Step 29.
• Disconnect free solenoid valve connector.
SOLENOID VALVE CONNECTOR TERMINAL No Inspect free solenoid valve, then go to Step 29.
B AND GROUND.
CONNECTOR TERMINAL 254 AND GROUND. No Repair wiring harness between free solenoid valve and
03-03-5

• Disconnect lock solenoid valve connector.
SOLENOID VALVE CONNECTOR TERMINAL No Inspect lock solenoid valve, then go to Step 29.
B AND GROUND.
CONNECTOR TERMINAL 253 AND GROUND. No Repair wiring harness between lock solenoid valve and
9 INSPECT FOR CONTINUITY BETWEEN PCM Yes Go to next step.
CONNECTOR TERMINAL 202/204/206 AND No Repair wiring harness between PCM and ground, then go to
GROUND. Step 29.
• Shift select lever to N position.
11 INSPECT FOR CONTINUITY BETWEEN Yes Repair wiring harness between PCM and transfer neutral
TRANSFER NEUTRAL SWITCH CONNECTOR switch, then go to Step 29.
13 INSPECT FOR CONTINUITY BETWEEN Yes Go to next step.
TRANSFER NEUTRAL SWITCH CONNECTOR No Repair wiring harness between transfer neutral switch and
• Shift select lever to 2 H position.
15 INSPECT FOR CONTINUITY BETWEEN 4X4 Yes Repair wiring harness between PCM and 4x4 indicator
INDICATOR SWITCH CONNECTOR switch, then go to Step 29.
16 INSPECT 4X4 INDICATOR SWITCH. Yes Go to next step.
• Is it OK? No Replace 4x4 indicator switch, then go to Step 29.
17 INSPECT FOR CONTINUITY BETWEEN 4X4 Yes Go to next step.
INDICATOR SWITCH CONNECTOR No Repair wiring harness between 4x4 indicator switch and
19 INSPECT FOR CONTINUITY BETWEEN RFW Yes Repair wiring harness between RFW switch, then go to Step
SWITCH CONNECTOR TERMINAL A AND 29.
GROUND. No Go to next step.
20 INSPECT RFW SWITCH. Yes Go to next step.
• Is it OK? No Replace RFW switch, then go to Step 29.
SWITCH CONNECTOR TERMINAL BAND No Repair wiring harness between RFW switch and ground,
GROUND. then go to Step 29.
22 INSPECT FOR CONTINUITY BETWEEN RFW Yes Repair wiring harness between RFW main switch and PCM,
MAIN SWITCH CONNECTOR TERMINAL D then go to Step 29.
AND GROUND. No Go to next step.
03-03-6

23 INSPECT RFW MAIN SWITCH. Yes Go to next step.
• Is it OK? No Replace RFW main switch.
MAIN SWITCH CONNECTOR TERMINAL B No Repair wiring harness between RFW main switch and
AND GROUND. ground, then go to Step 29.
25 INSPECT ONE-WAY CHECK VALVE. Yes Go to next step.
• Is it OK? No Replace one-way check valve, then go to Step 29.
26 INSPECT RFW ACTUATOR. Yes Go to next step.
• Is it OK? No Replace RFW actuator, then go to Step 29.
27 INSPECT VACUUM IN VACUUM HOSES. Yes Go to next step.
• Is it OK? No Replace vacuum in vacuum hoses, then go to Step 29.
28 INSPECT PCM. Yes Go to next step.
• Is it OK? No Repair or replace PCM, then go to next step.
29 DOES RFW OPERATE FROM FREE TO Yes Troubleshooting completed. Explain repairs to customer.
LOCK? No Inspect malfunction symptoms again, then repeat from Step
• Turn engine switch ON. 1 if malfunction occurs again.
• Move selector lever from 2H to 4H position.
• Does RFW operate from free to lock?
NO.3 NOISE
3 NOISE
DESCRIPTION Noise is heard from front differential.
• Joint shaft bearing abrasion or damage.
• RFW hub abrasion
• Conventional front differential parts malfunction
1 INSPECT JOINT SHAFT BEARING. Yes Go to next step.
• Is it OK? No Replace joint shaft bearing.
2 INSPECT RFW HUB Yes Go to next step.
• Is it OK? No Replace RFW hub.
3 INSPECT JOINT SHAFT. Yes Go to next step.
• Is it OK? No Replace joint shaft.
4 INSPECT CONVENTIONAL FRONT Yes Go to next step.
DIFFERENTIAL PARTS. No Replace defective part(s).
• Are they OK?
5 VERIFY THERE IS NO NOISE. Yes Troubleshooting completed. Explain repairs to customer.
• Has front differential noise stopped? No Inspect malfunction symptoms again, then repeat from Step
1 if malfunction occurs again.
03-03-7
NO.4 OIL LEAKAGE
dcf030327100w07
4 lOlL LEAKAGE
I
DESCRIPTION The oil leaks from front differential.
• Poor installation of the RFW control box .
• Malfunction of conventional front differential parts .
1 VERIFY CONDITION RFW CONTROL BOX Yes Go to next step.
INSTALLATION No Install RFW control box securely, then go to Step 3.
• Is RFW control box installed completely?
DIFFERENTIAL PARTS. No Replace defective part(s).
• Are they OK?
3 VERIFY THERE IS NO OIL LEAKAGE FROM Yes Inspect malfunction symptoms again, then repeat from Step
FRONT DIFFERENTIAL. 1 if malfunction still occurs.
• Is there any oil leakage from front No Troubleshooting completed. Explain repairs to customer.
differential?
03-03-8
SYMPTOM TROUBLESHOOTING [4x4 control module]
03-03 SYMPTOM TROUBLESHOOTING [4x4 control

module] .
4x4 CONTROL SYSTEM WIRING DIAGRAM NO.2 4x4/4L INDICATOR DOSE NOT
[4x4 control module] .....•....•..• 03-03-1 ILLUMINATE [4x4 control module] .•• 03-03-5
PRECAUTION [4x4 control module] ... 03-03-2 NO.3 NO CHANGE FORM 4x2 TO 4x4
SYMPTOM TROUBLESHOOTING [4x4 control module] ...•••....•..•. 03-03-6
[4x4 control module] ...•.......•.. 03-03-2 NO.4 NO CHANGE FORM 4H TO 4L
NO.1 NO RFW OPERATION [4x4 control module] •••......•.••.. 03-03-7
[4x4 control module] ....••.••.•.•. 03-03-3 NO.5 NOISE [4x4 control module] .•... 03-03-9
NO.6 OIL LEAKAGE
[4x4 control module] ....•..•.••.... 03-03-10
4x4 CONTROL SYSTEM WIRING DIAGRAM [4x4 control module]

id03031 0802800
4x4
CONTROL
B+ IG1
MODULE
TRANSFER CASE
r---~Cr--------.
CLUTCH COIL
TCM
MOTOR COMPONENT
DLC
4x4SWITCH
DIGITAL TR SENSOR J } - - - - - (
FREE SOLENOID
arnffw00001937
03-03-1
PRECAUTION [4x4 control module]
id03031 0801500
• This section only mentions unique symptoms of the trouble caused by 4x4 system,
Inspect and repair if necessary for trouble caused by other sources,
• Inspect the connector and terminal connections when inspecting the wiring harness,
(The cause of the malfunction may be a poor connection in the connectors, terminals, or wiring harness,)
Quick Diagnosis Chart
x: Applicable
Possible factor
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1 No RFW operation X X XX X X XX X X XX
2 4x4/4L indicator dose not illuminate X X X
3 No change from 4x2 to 4x4 X X XX X X
4 No change from 4H to 4L X X X X X X
5 Noise X X XX X X X X X
6 Oil leakage X X X X X XX X
arnffw00001938

id03031 0800300
• Verify the symptoms, and perform troubleshooting according to the appropriate number,
No, Symptom Description
1 • Motor component (position sensor) malfunction
• 4x4 control module malfunction
No RFW operation • Free solenoid valve malfunction
• Related fuses and lor harnesses malfunction
2 • Instrument cluster malfunction
4x4/4L indicator dose not illuminate • TCM malfunction
No change form 4x2 to 4x4 • TCM malfunction
• Drive chain malfunction
No change form 4H to 4L • TCM malfunction
• Digital TR sensor malfunction
03-03-2

5 • Joint shaft bearing abrasion or damage
Noise • Incorrect tire pressure
• Improper oil level
• Transfer bearing damaged
• Transfer gear damaged
• Transfer drive chain damaged
6 • RFW control box malfunction
• Transfer case malfunction
Oil leakage • Improper oil level
• Loosened sealing bolts
• Breather clogging
• Improper oil seal
NO.1 NO RFW OPERATION [4x4 control module]

id03031 0802000
1 NO RFW OPERATION
DESCRIPTION RFW dose not change from lock to free or from free to lock.
TROUBLESHO
OTING HINTS
AANDGROUND valve connector.
• Disconnect free solenoid valve connector. Then go to Step 14.
• Measure voltage between free solenoid valve
connector terminal A and ground.
SOLENOID VALVE CONNECTOR TERMINAL No Inspect free solenoid valve.
B AND GROUND Then go to Step 14.
3 MEASURE VOLTAGE BETWEEN 4x4 Yes Go to next step.
CONTROL MODULE CONNECTOR No Repair wiring harness between free solenoid valve and 4x4
TERMINAL V AND GROUND control module.
• Is the voltage greater than 10 V? Then go to Step 14.
AANDGROUND valve connector.
• Disconnect free solenoid valve connector. Then go to Step 14.
• Measure voltage between free solenoid valve
connector terminal A and ground.
SOLENOID VALVE CONNECTOR TERMINAL No Inspect lock solenoid valve.
BANDGROUND Then go to Step 14.
03-03-3

CONTROL MODULE CONNECTOR No Repair wiring harness between lock solenoid valve and 4x4
TERMINAL V AND GROUND control module.
• Is the voltage greater than 10 V? Then go to Step 14.
7 INSPECT FOR CONTINUITY BETWEEN 4x4 Yes Go to next step.
CONTROL MODULE CONNECTOR No Repair wiring harness between 4x4 control module and
TERMINAL W, X AND GROUND ground.
• Turn engine switch OFF. Then go to Step 14.
CONTROL MODULE CONNECTOR No Repair related wiring harness and related fuses.
TERMINAL T, Y, Z AND GROUND Then go to Step 14.
9 INSPECT 4x4 SWITCH Yes Go to next step.
• Is 4x4 switch OK? No Repair or replace 4x4 switch.
Then go to step 14.
10 INSPECT CONTINUITY FOR 4x4 SWITCH Yes Go to next step.
• Between 4x4 switch connector terminal A No Repair wiring harness between 4x4 switch and 4x4 control
and 4x4 control module terminal G. module.
• Between 4x4 switch connector terminal C Then go to Step 14.
and 4x4 control module terminal F.
• Between 4x4 switch connector terminal F
and ground.
11 INSPECT ONE-WAY CHECK VALVE Yes Go to next step.
• Is one-way check valve OK? No Replace one-way check valve.
Then go to step 14.
12 INSPECT RFW ACTUATOR Yes Go to next step.
• Is RFW actuator OK? No Replace RFW actuator.
Then go to step 14.
13 INSPECT VACUUM HOSE Yes Go to next step.
• Is vacuum hose OK? No Repair or Replace vacuum hose.
Then go to step 14.
14 • Verify test results.
- If normal, return to the diagnostic index to service any additional symptoms.
- If malfunction remains, inspect the related Service Bulletins and/or On-line Repair Information and perform
repair or diagnosis.
• If the vehicle is repaired, troubleshooting completed.
• If the vehicle is not repaired or additional diagnostic information is not available, replace the 4x4 control module.
03-03-4
NO.2 4x4/4L INDICATOR DOSE NOT ILLUMINATE [4x4 control module]
id03031 0802600
2 4x4/4L INDICATOR DOSE NOT ILLUMINATE

DESCRIPTION 4x4/4L indicator dose not illuminate when select 4H or 4L position.
TROUBLESHO • Instrument cluster malfunction

• TCM malfunction
OTING HINTS
1 INSPECT CONTINUITY FOR 4x4 CONTROL Yes Go to next step.
MODULE AND TCM No Repair wiring harness between 4x4 control module terminal
• Between 4x4 control module terminal Sand and TCM.
TCM terminal BB. Then go to Step 5.
• Between 4x4 control module terminal Rand
TCM terminal BA.
2 INSPECT CONTINUITY FOR TCM AND Yes Inspect the instrument cluster.
INSTRUMENT CLUSTER Then go to next step.
• Between TCM terminal N and instrument No Repair wiring harness between TCM and instrument cluster.
cluster terminal 1D. Then go to Step 5.
• Between TCM terminal R and instrument
cluster terminal 1F.
• If the vehicle is not repaired or additional diagnostic information is not available, replace the TCM.
03-03-5
NO.3 NO CHANGE FORM 4x2 TO 4x4 [4x4 control module]
id03031 0802700
3 NO CHANGE FORM 4x2 TO 4x4

DESCRIPTION 4x4 system dose not operate when select 4H position.
TROUBLESHO • TCM malfunction
OTING HINTS • 4x4 control module malfunction
• Drive chain malfunction
• Is 4x4 switch OK? No Repair or replace 4x4 switch.
Then go to step 10.
AND 4x4 CONTROL MODULE No Repair wiring harness between 4x4 switch and 4x4 control
• Between 4x4 switch connector terminal A module.
and 4x4 control module terminal G. Then go to Step 10.
• Between 4x4 switch connector terminal C
and ground.
MODULE AND MOTOR COMPONENT (SHIFT No Repair wiring harness between 4x4 control module and
MOTOR) transfer case connector.
• Between 4x4 control module connector Then go to Step 10.
terminal A, B and transfer case connector
terminal C.
• Between 4x4 control module connector
terminal C, D and transfer case connector
terminal F.
4 INSPECT MOTOR COMPONENT (SHIFT Yes Go to next step.
MOTOR) No Repair or replace motor component.
• Is motor component (shift motor) OK? Then go to Step 10.
MODULE AND MOTOR COMPONENT No Repair wiring harness between 4x4 control module and
(POSITION SENSOR) transfer case connector.
terminal J and transfer case connector
terminal E.
terminal I and transfer case connector
terminal B.
terminal L and transfer case connector
terminal A.
terminal H and transfer case connector
terminal D.
6 INSPECT MOTOR COMPONENT (POSITION Yes Go to next step.
SENSOR) No Repair or replace motor component.
• Is motor component (position sensor) OK? Then go to Step 10.
03-03-6
9 INSPECT TRANSFER Yes Go to next step.
• Is transfer OK? No Overhaul and check for wear and damage.
Replace if necessary.
Then go to Step 10.
• If the vehicle is not repaired or additional diagnostic information is not available, replace the 4x4 Control Module.
NO.4 NO CHANGE FORM 4H TO 4L [4x4 control module]

id03031 0802900

TROUBLESHO • TCM malfunction
OTING HINTS • 4x4 control module malfunction
• TR sensor malfunction
• Is 4x4 switch OK? No . Repair or replace 4x4 switch.
Then go to step 11.
AND 4x4 CONTROL MODULE No Repair wiring harness between 4x4 switch and 4x4 control
• Between 4x4 switch connector terminal A module.
and 4x4 control module terminal G. Then go to Step 11.
• Between 4x4 switch connector terminal B
and ground.
3 INSPECT DIGITAL TR SENSOR Yes Go to next step.
• Is digital TR sensor OK? No Repair or replace digital TR sensor.
Then go to step 11 .
4 INSPECT CONTINUITY FOR DIGITAL TR Yes Go to next step.
SENSOR AND 4x4 CONTROL MODULE No Repair wiring harness between digital TR sensor and 4x4
• Between digital TR sensor connector control module.
terminal J and 4x4 control module terminal Then go to Step 11.
E.
MODULE AND MOTOR COMPONENT (SHIFT No Repair wiring harness between 4x4 control module and
MOTOR) transfer case connector.
terminal A, B and transfer case connector
terminal C.
terminal C, 0 and transfer case connector
terminal F.
6 INSPECT MOTOR COMPONENT (SHIFT Yes Go to next step.
MOTOR) No Repair or replace motor component.
• Is motor component (shift motor) OK? Then go to Step 11.
03-03-7

MODULE AND MOTOR COMPONENT No Repair wiring harness between 4x4 control module and
(POSITION SENSOR) transfer case connector.
terminal J and transfer case connector
terminal E.
terminal I and transfer case connector
terminal B.
terminal L and transfer case connector
terminal A.
terminal H and transfer case connector
terminal D.
8 INSPECT MOTOR COMPONENT (POSITION Yes Go to next step.
SENSOR) No Repair or replace motor component.
• Is motor component (position sensor) OK? Then go to Step 11.
• If the vehicle is not repaired or additional diagnostic information is not available, replace the 4x4 Control Module.
03-03-8
NO.5 NOISE [4x4 control module]
id030310802400
5 NOISE
DESCRIPTION Noise is heard from front differential or transfer case.
• Joint shaft bearing abrasion or damage
TROUBLESHO • Conventional front differential parts malfunction
OTING HINTS • Incorrect tire pressure
• Improper oil level
• Transfer bearing damaged
• Transfer gear damaged
• Transfer drive chain damaged
nr"""''''ure
• Is it OK?
2 INSPECT RFW HUB
• Is it OK?
3 INSPECT JOINT SHAFT
• Is it OK?
4 INSPECT CONVENTIONAL FRONT
DIFFERENTIAL PARTS
• Are they OK?
5 INSPECT TIRE PRESSURE
• Are they OK?
6 INSPECT TRANSFER OIL LEVEL
• Is oil level OK?
7 INSPECT TRANSFER INNER PARTS
• Transfer bearing Overhaul and check for wear and damage.
• Transfer gear Replace if necessary.
• Transfer drive chain
• Are they OK?
-If normal, return to the diagnostic index to service any additional symptoms.
• If the vehicle is not or additional information is not available.
03-03-9
NO.6 OIL LEAKAGE [4x4 control module]
id03031 0802500
6 OIL LEAKEGE
DESCRIPTION The oil leaks from front differential or transfer case.
• Transfer case malfunction
TROUBLESHO
OTING HINTS • Improper oil level
• Loosened sealing bolts
• Breather clogging
• Improper oil seal
1 VERIFY RFW CONTROL BOX INSTALLATION Yes Go to next step.
CONDITION No Install RFW control box securely, then go to Step.
• Is RFW control box installed completely?
DIFFERENTIAL PARTS No Replace defective part (s).
• Are they OK?
3 INSPECT TRANSFER CASE Yes Go to next step.
• Is it OK? No Replace transfer case.
4 INSPECT TRANSFER OIL LEVEL Yes Go to next step.
• Is oil level OK? No Adjust the oil level.
5 INSPECT TRANSFER SEALING BOLTS Yes Go to next step.
• Are sealing bolts OK? No Re-tighten the sealing bolts.
6 INSPECT BREATHER NIPPLE FOR Yes Go to next step.
CLOGGING No Clean or replace breather nipple.
• Is it OK?
7 INSPECT OIL SEAL Yes Go to next step.
• Is it OK? No Replace damaged oil seal.
• If the vehicle is not repaired or additional diagnostic information is not available.
03-03-10
GENERAL PROCEDURES
GENERAL PROCEDURES
(FRONT AND REAR AXLES) ....... 03-10-1
GENERAL PROCEDURES (FRONT AND REAR AXLES)

dcf031000000w01
Wheel And Tire Installation

1. When installing the wheels and tires, tighten the wheel nuts in a criss-cross pattern to the following tightening
torque.
Tightening torque
88.2-117.6 N·m {9.0-12.0 kgf.m, 65.0-87.0 ft.lbf}
1. Disconnect the negative battery cable before performing any work that requires handling of connectors.
Suspension Links Removal/Installation

1. For the joint sections with rubber bushings, raise the vehicle using a lift, and then temporarily tighten the
installation bolts and nuts. Lower the vehicle to the ground and tighten them completely with the specified
torque.
Brake Lines Disconnection/Connection
Caution
• Brake fluid will damage painted surfaces. If brake fluid does get on a painted surface, wipe it off
immediately.
1. Tighten the brake pipe flare nut using the SST (49 0259 770B). Be sure to modify the brake pipe flare nut
tightening torque to allow for use of a torque wrench-SST combination.
(See 00-00-16 Torque Formulas.)
2. If any brake line has been disconnected anytime during the procedure, add brake fluid, bleed the brakes, and
inspect for leakage after the procedure has been completed.
03-10-1
FRONT AXLE
03-11 FRONT AXLE

FRONT AXLE LOCATION INDEX WHEEL HUB, STEERING KNUCKLE
[4x2 (EXCEPT Hi-Rider)] ...•.•••... 03-11-1 INSPECTION [Hi-Rider, 4x4] .......• 03-11-4
FRONT AXLE LOCATION INDEX WHEEL HUB, STEERING KNUCKLE
[Hi-Rider] ....•.•.•..•.•..•...... 03-11-2 REMOVAUINSTALLATION
FRONT AXLE LOCATION INDEX [4x2 (EXCEPT Hi-Rider)] •...•••..•. 03-11-4
[4x4] .....••.•..........•.•••..• 03-11-2 WHEEL HUB, STEERING KNUCKLE
WHEEL HUB BOLT REPLACEMENT REMOVAUINSTALLATION
[Hi-Rider,4x4] ..•.•......•...•... 03-11-3 [Hi-Rider] •.••.•....••......•...•• 03-11-8
WHEEL HUB, STEERING KNUCKLE WHEEL HUB, STEERING KNUCKLE
INSPECTION REMOVAUINSTALLATION [4x4] ....• 03-11-14
[4x2 (EXCEPT Hi-Rider)] ...•.•••... 03-11-3
FRONT AXLE LOCATION INDEX [4x2 (EXCEPT Hi-Rider)]

dcf03110400Ow01
DBG311ZWB001
Wheel hub, steering knuckle

(See 03-11-3 WHEEL HUB, STEERING KNUCKLE
INSPECTION [4x2 (EXCEPT Hi-Rider)].)
REMOVAUINSTALLATION [4x2 (EXCEPT Hi-
Rider)].)
03-11-1
FRONT AXLE
FRONT AXLE LOCATION INDEX [Hi-Rider]
dcf03110400Ow02
""""-----<D
DBG311ZWB003
Wheel hub bolt 2 Wheel hub, steering knuckle

(See 03-11-3 WHEEL HUB BOLT REPLACEMENT (See 03-11-4 WHEEL HUB, STEERING KNUCKLE
[Hi-Rider, 4x4].) INSPECTION [Hi-Rider, 4x4])
REMOVAUINSTALLATION [Hi-Rider])
FRONT AXLE LOCATION INDEX [4x4]

dcf03110400Ow03
DBG311ZWB002
Wheel hub bolt 2 Wheel hub, steering knuckle

(See 03-11-3 WHEEL HUB BOLT REPLACEMENT (See 03-11-4 WHEEL HUB, STEERING KNUCKLE
[Hi-Rider,4x4].) INSPECTION [Hi-Rider, 4x4])
(See 03-11-14 WHEEL HUB, STEERING
KNUCKLE REMOVAUINSTALLATION [4x4].)
03-11-2
FRONT AXLE
WHEEL HUB BOLT REPLACEMENT [Hi-Rider, 4x4]

dcf03113306Ow01
1. Remove the brake caliper component and disc plate.

2. Remove the hub bolt using the SST.
3. Place a new wheel hub bolt in the wheel hub.
ABR6312W024
4. Install the wheel hub bolt by placing a proper

sized washer on the hub, and tightening the nut HUB BOLT
BRASS BAR WASHER
WHEEL HUB, STEERING KNUCKLE INSPECTION [4x2 (EXCEPT Hi-Rider)]

dcf03110406Ow01
Wheel Bearing Looseness Inspection

1. After jacking up the vehicle and supporting it at the specified places with safety stands, inspect for noticeable
bearing play by holding the top and bottom of the tire.
Maximum wheel bearing play [4x2 (Except Hi-Rider)]

o mm {O in}
Preload Adjustment
1. Inspect that the tire rotates smoothly when rotated strongly, and there is no rough feeling or no abnormal noise
from the bearing.
2. Attach a pull scale to a hub bolt and measure the preload.
Front wheel axle preload [4x2 (Except Hi-Rider)]

5.6-11.2 N {0.58-1.14 kgf, 1.26-2.51 Ibf}
• If not an specification, adjust the front wheel bearing preload.
When replacing the bearing

1. Remove the brake caliper component and suspend it by a rope.
2. Remove the hub cap, pull out the cotter pin and remove the set cover.
3. Tighten the wheel hub locknut with 20-30 N·m {2.1-3.0 kgf·m, 15-22 ft.lbf} to fit the bearing.
4. Loosen the locknut to the extent that it can be turned by hand.
5. Attach a pull scale to a hub bolt and adjust the preload.
Front wheel axle preload [4x2 (Except Hi-Rider)]

5.6-11.2 N {0.58-1.14 kgf, 1.26-2.51 Ibf}
6. Tighten the locknut until the reading reaches the specified amount.
03-11-3
FRONT AXLE
WHEEL HUB, STEERING KNUCKLE INSPECTION [Hi-Rider, 4x4]
dcf03110406Ow02
Wheel Bearing Play Inspection

1. After jacking up the vehicle and supporting it at the specified places with safety stands, inspect for noticeable
bearing play by holding the top and bottom of the tire.
Maximum front wheel bearing play [Hi-Rider, 4x4]

0.05 mm {0.002 in}
WHEEL HUB, STEERING KNUCKLE REMOVAL/INSTALLATION [4x2 (EXCEPT Hi-Rider)]

dcf03110406Ow03
Caution
the following procedures, disconnect the ABS wheel-speed sensor harness connector (axle side)
and fix it to an appropriate place where the sensor will not be pulled by mistake while servicing the
vehicle.

mimi) :
I
I
11 I I
441-<88
{4.50-5.99,
32.6-43.3}
""m 1m
157-209
{16.1-21.3,
19-25
{2.0-2.5,
15-18}
116-154}
DBG311ZWB010
1 ABS wheel-speed sensor (with ABS) 8 Brake caliper component

2 Clip (See 03-11-5 Brake Caliper Component Removal
Note.)
3 Hub cap
9 Hub and disc plate component
4 Cotter pin (See 03-11-7 Hub And Disc Plate Component
5 Set cover Installation Note.)
6 Locknut 10 Dust cover
7 Washer 11 Tie-rod end
(See 06-14-10 STEERING GEAR AND LINKAGE
03-11-4
FRONT AXLE
12 Knuckle arm 18 Hub bolt

13 Lower arm ball joint (See 03-11-5 Disc Plate, Wheel Hub, Hub Bolt
(See 02-13-5 TORSION BAR SPRING AND Removal Note.)
LOWER ARM REMOVAUINSTALLATION [4x2 (See 03-11-7 Hub Bolt Installation Note.)
(EXCEPT Hi-Rider)].) 19 Outer bearing inner race
14 Upper arm ball joint 20 Oil seal
(See 02-13-15 Front Upper Arm Ball Joint Removal (See 03-11-7 Oil Seal Installation Note.)
Note.) 21 Inner bearing inner race
15 Steering knuckle 22 Inner bearing outer race
16 Disc plate (See 03-11-6 Inner Bearing Outer Race, Outer
(See 03-11-5 Disc Plate, Wheel Hub, Hub Bolt Bearing Outer Race Removal Note.)
Removal Note.) (See 03-11-7 Outer Bearing Outer Race, Inner
(See 03-11-7 Hub And Disc Plate Component Bearing Outer Race Installation Note.)
Installation Note.) 23 Outer bearing outer race
17 Wheel hub (See 03-11-6 Inner Bearing Outer Race, Outer
(See 03-11-5 Disc Plate, Wheel Hub, Hub Bolt Bearing Outer Race Removal Note.)
Removal Note.) (See 03-11-7 Outer Bearing Outer Race, Inner
(See 03-11-7 Hub And Disc Plate Component Bearing Outer Race Installation Note.)
Installation Note.) 24 ABS sensor rotor (with ABS)
(See 03-11-6 ABS Sensor Rotor Removal Note.)
(See 03-11-6 ABS Sensor Rotor Installation Note.)
Brake Caliper Component Removal Note

1. Remove the brake caliper component installation
bolt, and suspend it with a cable in place out of
the way.
DBG311ZWB011
Disc Plate, Wheel Hub, Hub Bolt Removal Note
Note
• The hub bolt does not need to be removed unless replacing them.
1. After putting markings on the disc plate and the

wheel hub, remove the bolt and disassemble the
plate and hub.
2. Remove the hub bolt using a press as necessary.
DBG311ZWB012
03-11-5
FRONT AXLE
Inner Bearing Outer Race, Outer Bearing Outer Race Removal Note
Note
• When inner bearing outer race is removed, inner race and oil seal are removed together.
1. Remove the bearing outer race using a suitable

round bar and a hammer. For other side, reverse
the wheel hub and remove the outer race.
DBG311ZWB004
ABS Sensor Rotor Removal Note
Note
• The sensor rotor does not need to be removed unless it is being replaced.
1. Remove the sensor rotor using a chisel.
ABR6312W002
ABS Sensor Rotor Installation Note

1. Set the SST shown in the figure.
ABR6312W003
2. Press the new sensor rotor in unit flush with the

end of the wheel hub using the SST and a press. -0.3-0.3 mm
{-0.012-0. 011 in}
ABS SENSOR
ROTOR
WHEEL HUB
ABR6312W023
03-11-6
FRONT AXLE
Outer Bearing Outer Race, Inner Bearing Outer Race Installation Note
1. Install the bearing outer race using the SSTs and ,------------------------,
a press. For other side, reverse the wheel hub
and install the outer race. OUTSIDE BEARING
IU':!'SS'"''
DBG311 ZWB005
Oil Seal Installation Note

1. After inserting the bearing in the hub, tap in the oil
seal until it is flush with the hub end surface using
the SST.
2. Apply grease to the oil seal lip.
Hub Bolt Installation Note

1. Press new hub bolts into the wheel hub using a
press.
DBG311ZWB006
Hub And Disc Plate Component Installation Note

1. Apply grease to the areas indicated in the figure.
Grease amount
68-76 g {2.5-2.6 oz}
2. Install the hub and disc plate component, then

adjust the preload. (See 03-11-3 WHEEL HUB,
STEERING KNUCKLE INSPECTION [4x2
DBG311ZWB017
03-11-7
FRONT AXLE
WHEEL HUB, STEERING KNUCKLE REMOVAUINSTALLATION [Hi-Rider]
dcf0311 0406OW04
Caution
possibly cause an open circuit in the harness if it is pulled by mistake. Before performing the
following procedures, remove the ABS wheel-speed sensor (axle side) and fix it to an appropriate
place where the sensor will not be pulled by mistake while the vehicle is being serviced.

24.5-36.2 {2.5-3.6, 18.1-26.6}
19-25 {2.0-2.5, 15-18}
88.2-117.6
{9.00-11.99,
65.06-86.73}
WHEEL
BEARING
SIDE
DBG311ZWB013
1 ABS wheel-speed sensor (with ABS) 5 Brake caliper component

2 Hub cap (See 03-11-10 Brake Caliper Component Removal
Note)
3 Locknut
(See 03-11-9 Locknut Removal Note) 6 Disc plate
(See 03-11-13 Locknut Installation Note) 7 Tie-rod end ball joint
4 Wheel and tire (See 03-11-10 Tie-rod End Ball Joint Removal Note)
03-11-8
FRONT AXLE
8 Bolt (stabilizer) 14 ABS sensor rotor (with ABS) or spacer (without

(See 02-13-17 FRONT STABILIZER REMOVAU ABS)
INSTALLATION [Hi-Rider, 4x4].) 15 Retaining ring
9 Bolt (shock absorber) 16 Wheel bearing
10 Upper arm ball joint (See 03-11-11 Wheel Bearing Removal Note)
(See 02-13-15 Front Upper Arm Ball Joint Removal (See 03-11-12 Wheel Bearing Installation Note)
Note.) 17 Dust cover
11 Lower arm ball joint (See 03-11-11 Dust Cover Removal Note)
(See 02-13-9 TORSION BAR SPRING AND (See 03-11-12 Dust Cover Installation Note)
LOWER ARM REMOVAUINSTALLATION [Hi-Rider, 18 Steering knuckle
4x4j
19 Hub bolt
12 Wheel hub, steering knuckle, dust cover (See 03-11-11 Hub Bolt Removal Note)
13 Wheel hub component (See 03-11-12 Hub Bolt Installation Note)
(See 03-11-10 Wheel Hub Component Removal
Note)
(See 03-11-13 Wheel Hub Component Installation
Note)
Locknut Removal Note
Note
• Remove the locknut with the vehicle on level ground.
1. Knock the crimped portion of the locknut outward

using a small chisel and a hammer.

-----~----~ -- AVF6312W051
03-11-9
FRONT AXLE
1. Remove the brake caliper component, and
suspend it with rope.
AVF6312W002
Tie-rod End Ball Joint Removal Note

1. Remove the tie rod-nut.
2. Separate the tie-rod end from the steering
knuckle using the SSTs.
" I
" I
Wheel Hub Component Removal Note

1. Remove the wheel hub component using the
SSTs and a press.
AVF6312W004
2. If the bearing inner race remains on the front

wheel hub component, grind a section of the
bearing inner race until approx. 0.5 mm {0.02 in}
remains. Then remove it using a chisel.
AVF6312W005
03-11-10
FRONT AXLE
Wheel Bearing Removal Note
1. Remove the wheel bearing using the SSTs and a
press.
ABR6312W007
Dust Cover Removal Note
Note
• The dust cover does not need to be removed unless it is being replaced.
1. Mark the dust cover and steering knuckle for

proper installation.
MARK
ABR6312W008
2. Remove the dust cover using a chisel.
ABR6312W009
Hub Bolt Removal Note
Note
• The hub bolts do not need to be removed unless they are being replaced.
1. Remove the hub bolts using a press.
AVF6312W006
03-11-11
FRONT AXLE
1. Install the new hub bolts using a press.
AVF6312W007
DustCover Installation Note

1. Mark the new dust cover in the same way as the
removed one.
2. Align the marks of the new dust cover and the
knuckle.
ABR6312W010
3. Install the new dust cover using the SSTs and a

press.
, .
~. • I • I
DBG311ZWB015
Wheel Bearing Installation Note

1. Install the new wheel bearing using the SSTs and
a press.
ABR6312W012
03-11-12
FRONT AXLE
Wheel Hub Component Installation Note
1. Install the wheel hub component using the SSTs
and a press.
Locknut Installation Note
Note
• Install the locknut with the vehicle on level ground.
1. Install a new locknut and stake it as shown.
03-11-13
FRONT AXLE
WHEEL HUB, STEERING KNUCKLE REMOVAL/INSTALLATION [4x4]
dcf03110406OwOS
Caution'

24.5-36.2 {2.5-3.6, 18.1-26.6}
69.2-93.2
iii
~
235-314
{7.06-9.50, {24.o-32.0,
51.1-68.7} 174-231}
19-25
{2.0-2.5,
15-18}
mI~
~.' 10 . .
iii
I 0 1
DBG311ZWB014
1 Locknut 4 Tie-rod end ball joint

(See 03-11-15 Locknut Removal Note) (See 03-11-15 Tie-rod End Ball Joint Removal Note)
(See 03-11-19 Locknut Installation Note) 5 Bolt (stabilizer)
2 Brake caliper component 6 Bolt (shock absorber)
(See 03-11-15 Brake Caliper Component Removal
7 Upper arm ball joint
Note)
3 Disc plate
8 Lower arm ball joint
9 Wheel hub, steering knuckle, dust cover
03-11-14
FRONT AXLE
10 Oil seal 14 Dust cover

(See 03-11-16 Oil Seal Removal Note) (See 03-11-17 Dust Cover Removal Note)
(See 03-11-19 Oil Seal Installation Note) (See 03-11-18 Dust Cover Installation Note)
11 Wheel hub component 15 Steering knuckle
(See 03-11-16 Wheel Hub Component Removal 16 Hub bolt
Note) (See 03-11-17 Hub Bolt Removal Note)
(See 03-11-18 Wheel Hub Component Installation (See 03-11-17 Hub Bolt Installation Note)
Note)
12 Retaining ring
13 Wheel bearing
(See 03-11-16 Wheel Bearing Removal Note)
(See 03-11-18 Wheel Bearing Installation Note)
Locknut Removal Note

1. Knock the crimped portion of the locknut outward using a small chisel and a hammer.
2. Lock the hub by applying the brakes.
ABR6312W005

1. Remove the brake caliper component, and
.suspend it with rope.
ABR6312W015
Tie-rod End Ball Joint Removal Note

1. Remove the tie rod-nut.
2. Separate the tie-rod end from the steering
knuckle using the SSTs.
03-11-15
FRONT AXLE
Oil Seal Removal Note
1. Remove the oil seal by using a screwdriver.
Wheel Hub Component J:lemoval Note

1. Remove the wheel hub component using the
SSTs and a press.
• I
ABR6312W006
2. If the bearing inner race remains on the front

wheel hub component, grind a section of the
bearing inner race until approx. 0.5 mm {0.02 in}
remains. Then remove it using a chisel.
ABR6312W016
Wheel Bearing Removal Note

1. Remove the wheel bearing using the SSTs and a
press.
ABR6312W007
03-11-16
FRONT AXLE
Dust Cover Removal Note
Note
• The dust cover does not need to be removed unless it is being replaced.
1. Mark the dust cover and steering knuckle for

proper installation.
MARK
ABR6312W008
2. Remove the dust cover using a chisel.
Hub Bolt Removal Note
Note
• The hub bolts do not need to be removed unless they are being replaced.
1. Remove the hub bolts using a press.
ABR6312W019

1. Install the new hub bolts using a press.
ABR6312W022
03-11-17
FRONT AXLE
Dust Cover Installation Note
1. Mark the new dust cover in the same way as the
removed one.
2. Align the marks of the new dust cover and the
knuckle.
ABR6312W010
3. Install the new dust cover using the SSTs and a

press.
DBG311ZWB015
Wheel Bearing Installation Note

1. Install the new wheel bearing using the SSTs and
a press.
ABR6312W012
Wheel Hub Component Installation Note

1. Install the wheel hub component using the SSTs
and a press.
DBG311ZWB016
03-11-18
FRONT AXLE
Oil Seal Installation Note
1. Apply grease to the new oil seal lip.
2. Install the new oil seal flush with the knuckle using
the SSTs. PLATE
Locknut Installation Note

1. Install a new locknut and stake it as shown.
ORG I
0.5 mm {0.02 m}
03-11-19
REAR AXLE
03-12 REAR AXLE

REAR AXLE LOCATION INDEX ....... 03-12-1 AXLE SHAFT
REAR AXLE INSPECTION ........... 03-12-1 REMOVAUINSTALLATION ......... . 03-12-2
REAR AXLE ADJUSTMENT .......... 03-12-2
REAR AXLE LOCATION INDEX

dcf03120S00Ow01
Hi-Rider, 4x4
DCF312ZWB001
Axle shaft
(See 03-12-1 REAR AXLE INSPECTION.)
(See 03-12-2 REAR AXLE ADJUSTMENT.)
(See 03-12-2 AXLE SHAFT REMOVAU
INSTALLATION.)
REAR AXLE INSPECTION

dcf03122611Ow01
Wheel Bearing Play Inspection
1. Jack up the rear end and support it with safety stands.
2. Verify that there is no abnormal noise and that the tire rotates smoothly when forcefully rotated by hand.
3. With a hand on top of the tire, inspect the bearing play.
Rear wheel bearing play

0.05-0.25 mm {0.002-0.010 in}
4. If the bearing play exceeds the specification, adjust the bearing play.
03-12-1
REAR AXLE
REAR AXLE ADJUSTMENT
dcf03122611OW02
Wheel Bearing Play Adjustment

1. Adjust the bearing end play in the axial direction
using the following procedures. (Only when the
bearing is replaced.)
(1) Press one side of the rear axle shaft
components to the thrust bearing on the
differential.
(2) Measure the clearance between the bearing
housing and the axle housing (part A in the
figure).
(3) Select a shim that is 0.65-0.95 mm {0.026-
0.037 in} thicker than the clearance SHIM
measured in Step 2 and install it.
ABR6314W011
(4) Measure the clearance of the rear axle shaft
component on the opposite side using the
same procedure in Steps 1 and 2 above.
(5) Select a shim that is 0.05-0.25 mm {0.002-0.009 in} thicker than the clearance measured in Step 4 and
install it.
(6) Verify that the rear axle bearing end play is within a range of 0.05-0.25 mm {0.002-0.009 in}.
• If it is not within the range, adjust the rear axle bearing end play again.
Rear axle bearing play in axial direction

0.05-0.25 mm {0.002-0.009 in}
AXLE SHAFT REMOVAUINSTALLATION

dcf03122611 OW03
03-12-2
REAR AXLE
1mB 275-313
8 {28.1-31.9,203-230}
1mB
12.8-21.6 N'm 3
{131-220 kgf·cm,
114-191 in·lbf}
15
WITHABS
s;,b}"-..
19-25
{2.0-2.5,
16
~
."(2 ~1:;'
iii
~~"w~(J "~~."
108-128
{11.1-13.0,
79.7-94.4} Q
~~ I I" "
•
iii
6
*490259770B N·m {kgf.m, ft.lbf}
DBG312ZWB001
1 Brake drum 11 Bearing inner race

2 Parking brake cable connecting pin (See 03-12-6 Bearing Inner Race, Bearing Locknut
Installation Note)
3 Brake pipe
12 Bearing spacer
4 Nut
13 Oil seal (bearing housing side)
5 Axle shaft and back plate component (See 03-12-6 Bearing Outer Race, Oil Seal (Bearing
(See 03-12-7 Axle Shaft and Back Plate
Housing Side) Installation Note)
Component, Shim Installation Note (Bearing play
adjustment)) 14 Bearing outer race
(See 03-12-5 Bearing Outer Race Removal Note)
6 Shim (See 03-12-6 Bearing Outer Race, Oil Seal (Bearing
(See 03-12-7 Axle Shaft and Back Plate
Housing Side) Installation Note)
Component, Shim Installation Note (Bearing play
adjustment)) 15 Back plate component
7 ABS sensor rotor (with ABS) 16 Axle shaft
(See 03-12-4 ABS Sensor Rotor Removal Note) 17 Hub bolt
(See 03-12-6 ABS Sensor Rotor Installation Note) 18 Baffle
8 Bearing locknut 19 Oil seal (axle casing side)
(See 03-12-4 Bearing Locknut Removal Note) (See 03-12-5 Oil Seal (Axle Casing Side) Removal
(See 03-12-6 Bearing Inner Race, Bearing Locknut Note)
Installation Note) (See 03-12-5 Oil Seal (Axle Casing Side)
9 Lock washer Installation Note)
10 Bearing housing 20 O-ring
(See 03-12-4 Bearing Housing Removal Note)
03-12-3
REAR AXLE
ABS Sensor Rotor Removal Note
Warning
• When grinding, be careful of debris coming from the grinder or bearing collar. Always wear eye
protectors.
Caution
• Because the ABS sensor rotor and rear wheel hub edge are almost flush even if the axle shaft is
moved as far as it will go, be careful not to damage the rear wheel hub when grinding.
1. Grind a part of the ABS sensor rotor using a

grinder until 0.5 mm {0.02 in} remains, and then
brake it using a chisel and remove from the shaft.
Bearing Locknut Removal Note
Note
• Be careful when removing or installing the bearing locknuts for the left wheels because they are left
threaded (tightened by turning counterclockwise).
1. Set the SSTs as shown in the figure, and remove

the bearing locknut from the rear axle shaft.
Bearing Housing Removal Note

1. Remove the bearing and bearing housing using
the SSTs.
03-12-4
REAR AXLE
Bearing Outer Race Removal Note
1. After removing the bearing inner race and oil seal
from the rear wheel hub, tap lightly using a
suitable round bar to force out the outer race.
Oil Seal (Axle Casing Side) Removal Note

1. remove the oil seal from the axle casing using a
screwdriver.
Oil Seal (Axle Casing Side) Installation Note

1. Tap the oil seal in until it is flush with the end of
the axle casing using the SST. AXLE CASING
2. After installation, apply grease to the oil seal lip.
AXLE CASING
OIL SEAL
/
OIL SEAL PRESS IN VALUE: 40.0-41.0 mm {1.58-1.68 in}
ABR6314W007
03-12-5
REAR AXLE
Bearing Outer Race, Oil Seal (Bearing Housing Side) Installation Note
1. Press the bearing outer race and the oil seal ,----------------.,------
using the SSTs.
OIL SEAL BEARING

ABR6314WOOB
Bearing Inner Race, Bearing Locknut Installation Note

1. Set the SST and then press the bearing in until 3
to 5 threads of the bearing locknut mounting
screw of the axle shaft are visible above the top of
the bearing outer race.
2. Remove the SST, and then install the bearing
locknut to the axle shaft.
3. Tighten the bearing locknut using the SST (49
0603 635A) to press in the bearing inner race.
4. Remove the bearing locknut and install the lock
washer so that its tab fits into the groove of the
axle shaft.
5. Re-install the bearing locknut and tighten it to the
ABR6314W013
specified torque.
Tightening torque
275-313 N·m {28.1-31.9 kgf·m, 203-230 ft·lbf}
6. Bend the lock washer tab securely in the slot in

the locknut.
Caution
• The torque wrench must be attached
perpendicular to the SST.
ABR6314W010
ABS Sensor Rotor Installation Note
Note
• Install the ABS sensor rotor in the direction
shown in the figure. BEARING LOCKNUT SIDE
I
t I
\ I
1 f
ABR6314W012
03-12-6
REAR AXLE
1. Press the ASS sensor rotor in until it is flush with
the end of the bearing lock nut using the SST.
ABR6314W009
Axle Shaft and Back Plate Component, Shim Installation Note (Bearing play adjustment)
1. Adjust the bearing end play in the axial direction
using the following procedures. (Only when the
bearing is replaced.)
(1) Press one side of the rear axle shaft
components to the thrust bearing on the
differential.
(2) Measure the clearance between the bearing
housing and the axle housing (part A in the
figure).
(3) Select a shim that is 0.65-0.S5 mm {0.026-
0.037 in} thicker than the clearance SHIM
measured in Step 2 and install it.
ABR6314W011
(4) Measure the clearance of the rear axle shaft
component on the opposite side using the
same procedure in Steps 1 and 2 above.
(5) Select a shim that is 0.05-0.25 mm {0.002-0.00S in} thicker than the clearance measured in Step 4 and
install it.
(6) Verify that the rear axle bearing end play is within a range of 0.05-0.25 mm {0.002-0.00S in} .
• If it is not within the range, adjust the rear axle bearing end play again.
Rear axle bearing play in axial direction

0.05 -0.25 mm {0.002-0.00S in}
03-12-7
DRIVE SHAFT
03-13 DRIVE SHAFT

I
DRIVE SHAFT LOCATION INDEX ..... 03-13-1 FRONT DRIVE SHAFT

FRONT DRIVE SHAFT REMOVAUINSTALLATION ......... . 03-13-2
INSPECTION . .................... 03-13-1 FRONT DRIVE SHAFT
DiSASSEMBLy/ASSEMBLy ......... 03-13-4
DRIVE SHAFT LOCATION INDEX

dcf031325501w01
DBG313ZWB001
Front drive shaft

(See 03-13-1 FRONT DRIVE SHAFT
INSPECTION.)
(See 03-13-2 FRONT DRIVE SHAFT REMOVAU
INSTALLATION.)
(See 03-13-4 FRONT DRIVE SHAFT
DISASSEMBLY/ASSEMBLY.)
FRONT DRIVE SHAFT INSPECTION

dcf031325501w02
1. Verify that the drive shaft is not twisted or damaged.

• If there is any malfunction, replace the applicable part.
2. Inspect the dust boot for damage and cracks.
• If there is any malfunGtion, replace the applicable part.
3. Move the spline and joint up and down, left and right by hand and verify that there is no roughness.
• If there is any malfunction, replace the applicable part.
03-13-1
DRIVE SHAFT
FRONT DRIVE SHAFT REMOVAUINSTALLATION
dcf031325501 w03
Caution
place where the sensor will not be pulled by mistake while servicing the vehicle.
1. If removing the RH drive shaft, drain the front differential oil.

DBG313ZWB002
Wheel hub, steering knuckle 2 Drive shaft

(See 03-11-4 WHEEL HUB, STEERINGKNUCKLE (See 03-13-2 Drive Shaft Removal Note)
REMOVAUINSTALLATION [4x2 (EXCEPT Hi- (See 03-13-3 Drive Shaft Installation Note)
Rider)].) 3 Clip
REMOVAUINSTALLATION [Hi-Rider].)
(See 03-11-14 WHEEL HUB, STEERING
KNUCKLE REMOVAUINSTALLATION [4x4].)
Drive Shaft Removal Note
Caution
• Do not damage the dust cover or the ABS sensor rotor on the drive shaft. These parts cannot be
purchased separately. Replace the assembled unit if the dust cover or the ABS sensor rotor is
damaged.
• The sharp edges of the drive shaft can slice or puncture the oil seal. Be careful when removing the
drive shaft from the front differential.
03-13-2
DRIVE SHAFT
1. Remove the drive shaft by prying with a bar
inserted between the differential casing and the
drive shaft, as shown in the figure.
ABR6316W003
Drive Shaft Installation Note
Caution
• The sharp edges of the drive shaft can slice or puncture the oil seal. Be careful when installing the
drive shaft to the front differential .
• The oil seals are damaged easily if this procedure is not done correctly.
(LH)
1. Install a new clip onto the output shaft with the
opening facing upward. Ensure that the diameter
of the clip does not exceed the specification for
installation. OPENING
2. After installation, measure the outer diameter.
• If it exceeds the specification, repeat Steps
1-2 using a new clip.
OUTER
Outer diameter specification DIAMETER
31.2 mm {1.23 in}
3. Apply differential oil to the oil seal lip.

ABR6316W012
4. Insert the drive shaft into the output shaft.
5. Push the drive shaft into the wheel hub.
6. After installation, pull the output shaft side outer ring forward to confirm that the drive shaft is securely held by
the clip.
(RH)
1. Install a new clip onto the drive shaft with the
opening of a new clip faCing upward.
2. After installation, measure the outer diameter.
• If it exceeds the specification, repeat Steps
1-2 using a new clip.
Outer diameter specification

33.2 mm {1.31 in}
OUTER
DIAMETER
3. Install the drive shaft into the front differential.
4. Push the drive shaft into the wheel hub.
5. After installation, pull the front differential side
ABR6316W005
outer ring forward to confirm that the drive shaft is
securely held by the clip.
03-13-3
DRIVE SHAFT
FRONT DRIVE SHAFT DISASSEMBLY/ASSEMBLY
dcf031325501 w04
Caution
• Do not damage and remove the dust cover or the ABS sensor rotor on the drive shaft. These parts
cannot be purchased separately. Replace the assembled unit if the dust cover or the ABS sensor
rotor is damaged and removed.

RH iii
2
iii
1
LH
iii
1
3
-!j!
II
DBG313ZWB003
1 Boot band 6 Inner ring

(See 03-13-5 Boot Band Disassembly Note) (See 03-13-5 Balls, Inner Ring, Cage Disassembly
(See 03-13-7 Boot Band Assembly Note) Note)
2 Clip (See 03-13-6 Cage, Inner Ring, Balls, Snap Ring
Assembly Note)
3 Outer ring
(See 03-13-5 Outer Ring Disassembly Note) 7 Cage
(See 03-13-7 Outer Ring Assembly Note) (See 03-13-5 Balls, Inner Ring, Cage Disassembly
Note)
4 Snap ring
(See 03-13-6 Cage, Inner Ring, Balls, Snap Ring
(See 03-13-6 Cage, Inner Ring, Balls, Snap Ring
Assembly Note)
Assembly Note)
8 Boot
5 Balls
(See 03-13-6 Boot Disassembly Note)
(See 03-13-5 Balls, Inner Ring, Cage Disassembly
(See 03-13-6 Boot Assembly Note)
Note)
(See 03-13-6 Cage, Inner Ring, Balls, Snap Ring 9 Shaft and bell joint component
Assembly Note)
03-13-4
DRIVE SHAFT
Boot Band Disassembly Note
Note
• The wheel side boot band does not need to be removed unless replacing it.
1. Pry up the locking clips using a screwdriver.

2. Remove the band using pliers.
3. Slide the boot along the shaft to expose the jOint.
ABR6316W006
Outer Ring Disassembly Note

1. Mark the cage and outer ring for proper assembly.
Caution
• Mark with paint; do not use a punch.
2. Remove the clip using a screwdriver.

3. Remove the outer ring from the inner ring and the
balls.
4. Clean the grease away.
Balls, Inner Ring, Cage Disassembly Note

1. Mark the inner ring and cage.
Caution
• Mark with paint; do not use a punch.
2. Remove the snap ring using snap-ring pliers.

3. Disassemble the balls, inner ring, cage from the drive shaft as component.
4. Turn the cage approx. 22.5 degree and pull the .----------------------,
cage and balls away from the inner ring.
DBG313ZWB005
I
\",
03-13-5
DRIVE SHAFT
Boot Disassembly Note
Note
• The wheel side boot does not need to be removed unless replacing it or the bell joint and shaft
component.
• Do not strip the tape until the boot is assembled.
1. Wrap the shaft splines with tape.

2. Remove the boot.
TAPE
ABR6316W008
Boot Assembly Note

1. Fill the boot (wheel side) with the specified grease from a tube, not by hand.
Caution
• Do not touch the grease with your hand. Apply it from the tube to prevent foreign matter from
entering the boot.
Note
• The wheel side and differential side boots are different.
• Use the specified grease supplied in the boot kit.
Grease amount
110-130 g {3.88-4.58 oz}
2. With the splines of the shaft still wrapped in tape from disassembly, install the boot.
3. Remove the tape.
Cage, Inner Ring, Balls, Snap Ring Assembly Note

1. Align the marks and install the balls and cage to
CAGE BALLS
the inner ring in the direction shown in the figure.
Caution
• Install the cage with the offset facing the
snap ring groove. If incorrectly installed,
the drive shaft may become disengaged.
2. Install a new snap ring. SNAP RING INNER

GROOVE RING
DBG313ZWB006
03-13-6
DRIVE SHAFT
Outer Ring Assembly Note
1. Fill the outer ring and boot with the specified grease.
Caution
• Do not touch the grease with your hand. Apply it from the tube to prevent foreign matter from
entering the boot.
Note
• Use the specified grease supplied in the boot kit.
Grease amount
115-135 g {4.06-4.76 oz}
2. 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.
Front drive shaft standard length

LH: 507.8-517.8 mm {20.00-20.38 in}
RH: 596.7-606.7 mm {23.50-23.88 in}
6. Release any trapped air from the boots by

carefully lifting up the small end of each boot with
a cloth wrapped screwdriver.
Caution
• Be careful not to allow the grease to leak.
• Do not damage the boot.
7. Verify that the drive shaft length is within the

specification. \-
\
ABR6316W010
Boot Band Assembly Note

Differential side
1. Fold the band in the direction opposite to the
forward revolving direction of the drive shaft and
use pliers to pull it tight.
2. Lock the end of the band by bending the locking
clips.
Caution
• Install the band into the groove securely.
A6E6316W008
03-13-7
DRIVE SHAFT
Wheel side
1. Adjust clearance A by turning the adjusting bolt of
the SST.
~A
Clearance A ADJUSTING BOLT
2.9 mm {O.11 in}
1
00 0
A6E0350W012
2. Crimp the wheel side small boot band using the

SST. Verify that clearance B is within the
specification.
• If clearance B is more than the specification,
reduce clearance A of the SST and crimp the
boot again.
• If clearance B is less than the specification,
replace the boot band, increase clearance A
of the SST, and crimp the new boot.
Clearance B
2.4-2.8 mm {O.095-0.11 0 in}
A6E0350W013
3. Verify that the boot band does not protrude from

the boot band installation area.
• If it does, replace the boot band and repeat Steps 2 and 3.
4. Fill the boot with the repair kit grease.
5. Adjust clearance A by turning the adjusting bolt of the SST.
Clearance A
3.2 mm {O.13 in}
6. Crimp the wheel side big boot band using the SST.
7. Verify that clearance B is within the specification.
• If clearance B is more than the specification, reduce clearance A of the SST and crimp the boot again.
• If clearance B is less than the specification, replace the boot band, increase clearance A of the SST and
crimp the new boot.
Clearance B
2.4-2.8 mm {O.095-0.11 0 in}
8. Verify that the boot band does not protrude from the boot band installation area.
• If it does, replace the boot band and repeat Steps 7 and 8.
03-13-8
DIFFERENTIAL [FRONT]
03-14A DIFFERENTIAL [FRONT]

FRONT DIFFERENTIAL FRONT DIFFERENTIAL
LOCATION INDEX ................. 03-14A-1 REMOVAL/INSTALLATION ......... . 03-14A-2
FRONT DIFFERENTIAL OIL FRONT DIFFERENTIAL
INSPECTION ..................... 03-14A-1 DISASSEMBLY ..........•.•.••... • 03-14A-4
FRONT DIFFERENTIAL OIL FRONT DIFFERENTIAL ASSEMBLY ... 03-14A-8
REPLACEMENT .................. 03-14A-2
FRONT DIFFERENTIAL LOCATION INDEX

dcf03142710Ow01
DBG314ZWB052
Front differential
(See 03-14A-1 FRONT DIFFERENTIAL OIL
INSPECTION.)
(See 03-14A-2 FRONT DIFFERENTIAL OIL
REPLACEMENT.)
(See 03-14A-2 FRONT DIFFERENTIAL REMOVAU
INSTALLATION.)
(See 03-14A-4 FRONT DIFFERENTIAL
DISASSEMBLY.)
(See 03-14A-8 FRONT DIFFERENTIAL
ASSEMBLY.)
FRONT DIFFERENTIAL OIL INSPECTION

dcf031427000w01
2. Remove the oil-fill plug and the washer.
3. Inspect if the oil level is close to the rim of the oil-fill plug hole.
4. If the oil is not close to the rim of the oil-fill plug hole, add oil.
03-14A-1
U
5. Install the oil-fill plug with a new washer and
tighten.
OIL LEVEL PLUG
Tightening torque
~)
39.2-53.9 N·m {4.00-5.49 kgf·m, 29.0-39.7
ft·lbf}
WASHER
% DBG314ZWB001
FRONT DIFFERENTIAL OIL REPLACEMENT

dcf031427000w02
2. Remove the oil-fill plug.
3. Remove the drain plug and drain the oil.
4. Install the drain plug with a new washer and tighten.
Tightening torque
39.2-53.9 N·m {4.00-5.49 kgf·m, 29.0-39.7 ft.lbf}
5. Add the specified oil through the oil-fill plug hole.
Front differential oil

Type: API service GL-5
Viscosity (above -1 SOC): SAE 90
Viscosity (below -1S0C): SAE SO
Oil capacity (approx. quantity): 1.8-2.0 L {2.0-2.1 US qt, 1.6-1.7 Imp qt}
6. After adding the oil, perform the oil level inspection.

7. Install the oil-fill plug with a new washer and tighten.
Tightening torque
39.2-53.9 N·m {4.00-5.49 kgf·m, 29.0-39.7 ft.lbf}
FRONT DIFFERENTIAL REMOVAL/INSTALLATION

dcf031427100w02
Caution
the following procedures, remove the ABS wheel-speed sensor (axle side) and fix it to an
appropriate place where the sensor will not be pulled by mistake while servicing the vehicle.
1. Drain the front differential oil. (See 03-14A-2 FRONT DIFFERENTIAL OIL REPLACEMENT.)
2. Remove the front propeller shaft. (See 03-15-2 PROPELLER SHAFT REMOVAUINSTALLATION.)
5. Add front differential oil. (See 03-14A-2 FRONT DIFFERENTIAL OIL REPLACEMENT.) .
03-14A-2
~
APPLY SCREW LOCK AGENT
107-131
~)~~~6~'
5
,,~8-30 ~ 0 ____--v
$.----,
"/3
~ 4
,~
a. a'-r ·
"bSI!l<::if@)?'A"
fo107-131
APPLY SCREW/' ~11.0-13.3,
LOCK AGENT 79.0-96.6} 36.3-53.9
{3.71"'::5.49,
26.8-39.7}
1 Drive shaft 4 Front differential, joint shaft component

(See 03-13-2 FRONT DRIVE SHAFT REMOVAU (See 03-14A-3 Front Differential, Joint Shaft
INSTALLATION.) Component Removal Note.)
2 Vacuum hose 5 Front differential
3 RFW switch connector
Front Differential, Joint Shaft Component Removal Note

1. Set the transmission jack on the differential.
2. Remove the bolts and nuts indicated in the figure.
DBG314ZWB035
03-14A-3
3. Remove the front differential and joint shaft
component from the vehicle using the
transmission jack.
DBG314ZWB036
FRONT DIFFERENTIAL DISASSEMBLY

dcf031427100w03
~
o ~S);~
~
I@.
12
14
18
4
mil
DBG314ZWB037
1 Bolt 8 Side bearing outer race

2 Differential caSing 9 Locknut
3 Oil baffle (See 03-14A-5 Locknut Disassembly Note.)
4 Differential component 10 Washer
(See 03-14A-5 Differential Component Disassembly 11 Companion flange
Note.) (See 03-14A-6 Companion Flange Disassembly
5 Lock plate Note.)
6 Bearing cap 12 Oil seal
(See 03-14A-5 Bearing Cap Disassembly Note.) (See 03-14A-6 Oil Seal Disassembly Note.)
7 Adjusting screw
03-14A-4
13 Drive pinion 21 Bolt

(See 03-14A-6 Drive Pinion Disassembly Note.) 22 Ring gear
14 Front bearing inner race 23 Knock pin
15 Collapsible spacer (See 03-14A-7 Knock Pin Disassembly Note.)
16 Rear bearing inner race 24 Pinion shaft
(See 03-14A-6 Rear Bearing Inner Race 25 Pinion gear
Disassembly Note.)
26 Thrust washer
17 Spacer
27 Side gear
18 Front bearing outer race
(See 03-14A-7 Front Bearing Outer Race, Rear 28 Thrust washer
Bearing Outer Race Disassembly Note.) 29 Side bearing inner race
19 Rear bearing outer race (See 03-14A-7 Side Bearing Inner Race
(See 03-14A-7 Front Bearing Outer Race, Rear Disassembly Note.)
Bearing Outer Race Disassembly Note.) 30 Gear case
20 Differential carrier 31 Oil seal
Differential Component Disassembly Note

1. Install the differential component to the SSTs.
Bearing Cap Disassembly Note

1. Place a mark on one of the bearing caps so that
the left and right bearing caps won't get mixed up.
Use the mark for matching at the time of
assembly.
Locknut Disassembly Note

1. Hold the companion flange using the SST and
remove the locknut.
DBG314ZWB012
03-14A-S
1. Pull the companion flange out using the SST.
DBG314ZWB006
Oil Seal Disassembly Note

1. Remove the oil seal using a screw driver.
DBG314ZWB007
Drive Pinion Disassembly Note

1. Remove the drive pinion by tapping with a plastic
hammer.
Rear Bearing Inner Race Disassembly Note
Note
• Mark or otherwise distinguish between the front and rear inner races so that they are not mixed at the time
of reassembly.
1. Remove the rear bearing inner race using the

SST.
DBG314ZWB009
03-14A-6
Front Bearing Outer Race, Rear Bearing Outer Race Disassembly Note
Note
• Mark or otherwise distinguish between the front and rear outer races so that they are not mixed up at the
time of reassembly.
1. Remove the bearing outer race by using the two

grooves on the carrier and tapping the outer races
alternately.
DBG314ZWB010
Knock Pin Disassembly Note
Caution
• Insert the bar from the knock pin hole at the opposite side from where the ring gear is installed.
1. Secure the gear case in a vise and remove the

knock pin using a 4 mm {O.16 in} diameter bar
DBG314ZWB011
Side Bearing Inner Race Disassembly Note
Caution
• Mark the left bearing in order to install in the same position.
1. Remove the side bearing inner race from the gear

case using the SST.
BHJ0314W020
03-14A-7
FRONT DIFFERENTIAL ASSEMBLY
dcf031427100w04
184-284
{18.8-28.9, 136-209}
30 22.6-26.4
{16.7-2.69,
~, ~ r::r:":I
61
16.7-19.4} ~
11
~mDi
73-107 .~ 2
{7.5-10.7,
53.9-78.9}
1
19 61 -'---
18
17.7-25.4 ~ ml m
{1.81-2.59,______
13.1-18.7} ~
"'1 ~ mD
7
DBG314ZWB040
1 Gear case 14 Spacer

2 Thrust washer (See 03-14A-10 Spacer Assembly Note)
3 Side gear 15 Rear bearing inner race
(See 03-14A-12 Rear Bearing Inner Race Assembly
4 Thrust washer
Note.)
5 Pinion gear
16 Drive pinion
6 Pinion shaft (See 03-14A-12 Drive Pinion Assembly Note.)
7 Knock pin 17 Collapsible spacer
(See 03-14A-9 Knock Pin Assembly Note.)
18 Front bearing inner race
8 Ring gear
19 Oil seal (companion flange)
(See 03-14A-9 Ring Gear Assembly Note.)
(See 03-14A-13 Oil Seal (Companion Flange)
9 Side bearing inner race Assembly Note.}
(See 03-14A-9 Side Bearing Inner Race Assembly
20 Companion flange
Note.)
21 Washer
10 Bolt
22 Locknut
11 Differential carrier
(See 03-14A-13 Locknut Assembly Note.)
12 Front bearing outer race
23 Side bearing outer race
(See 03-14A-9 Front Bearing Outer Race Assembly
(See 03-14A-13'Side Bearing Outer Race, Adjusting
Note.)
Screw, Bearing Cap Assembly Note.)
13 Rear bearing outer race
(See 03-14A-10 Rear Bearing Outer Race
Assembly Note.)
03-14A-8
24 Adjusting screw 27 Differential casing

(See 03-14A-13 Side Bearing Outer Race, Adjusting 28 Oil seal (differential casing)
Screw, Bearing Cap Assembly Note.) (See 03-14A-15 Oil Seal (Differential Casing)
25 Bearing cap Assembly Note.)
(See 03-14A-13 Side Bearing Outer Race, Adjusting 29 Oil baffle
Screw, Bearing Cap Assembly Note.)
30 Bolt
26 Lock plate
Knock Pin Assembly Note

1. Assemble the side gears, thrust washer, pinion
gears, pinion shaft and knock pin. After
assembling the knock pin, make a crimp so that
the pin will not come out of the gear case.
DBG314ZWB014
Ring Gear Assembly Note

1. Coat the ring gear and gear case facing surfaces with locking agent.
2. Install the ring gear and tighten the bolt to the specified torque.
Tightening torque
68.6-83.3 N·m {7.00-8.49 kgf·m, 50.6-61.4 ft.lbf}
Side Bearing Inner Race Assembly Note
Caution
• Bearings should be assembled to the original positions.
1. Press the side gearings into the gear case using

the SST.
DBG314ZWB041
Front Bearing Outer Race Assembly Note

1. Press the front bearing outer race into the carrier
using the SST and a press.
~. I I •
" I II
DBG314ZWB042
03-14A-9
Rear Bearing Outer Race Assembly Note
1. Press the rear bearing outer race into the carrier
..'
DBG314ZWB043
Spacer Assembly Note

Pinion height adjustment
Note
• Use the installed spacer when adjusting.
• Be careful to install SSTs in the correct position and facing in the correct direction.
1. Assemble the spacer, rear bearing inner race,

and the SST (49 8531 568) on to the SST (49
8531 565) as shown in the figure.
2. Assemble the front bearing inner race, SST (49
8531 567), companion flange, washer and nut to
the SST (49 8531 565).
3. Tighten the nut to the extent that the SST (49
8531 565) can be turned by hand.
FRONT BEARING
DBG314ZWB068
4. Place the SST on the surface plate and set the

dial gauge to zero.
5. Place the SST (49 0660 555) on top of the SST
(498531 565), and then set the SST (49 0727
570) on top of the SST (49 0660 555).
A6A63192026
03-14A-10
6. Place the measuring probe of the dial gauge at
the point where the side bearing is installed in the
differential carrier and measure at the lowest
position. Measure the left and right sides.
7. Add the two (left and right) values obtained by the

measurements taken in Step 6 and then divide (t)
the total by 2. From this sum, subtract the sum of t
the number inscribed on the end of the drive ..........I-~~--O
pinion divided by 100. (If there is no figure
inscribed, use 0.) This is the pinion height e+
adjustment value.
Note
• For example, the measured results obtained
step 6 are 0.06 mm {0.0024 in} and 0.04 mm
{0.0016 in}, the formula is (0.06+0.04)/
2=0.05.
Therefore, replace it with a spacer 0.05 mm
{0.002 in} thicker than the currently used one.
Spacer table
Identification mark Thickness (mm {in}) Identification mark Thickness (mm {in})
08 3.080 {0.1213} 29 3.290 {0.1295}
09 3.095 {0.1220} 30 3.305 {0.1301}
11 3.110 {0.1224} 32 3.320 {0.1307}
12 3.125 {0.1230} 33 3.335 {0.1313}
14 3.140 {0.1234} 35 3.350 {0.1319}
15 3.155 {0.1242} 36 3.365 {0.1325}
17 3.170 {0.1248} 38 3.380 {0.1331}
18 3.185 {0.1254} 39 3.395 {0.1337}
20 3.200 fO.1260} 41 3.410 {0.1343}
21 3.215 {0.1266} 42 3.425 {0.1348}
23 3.230 {0.1271} 44 3.440 {0.1354}
24 3.245 {0.1278} 45 3.455 {0.1360}
26 3.260 {0.1283} 47 3.470 {0.1366}
27 3.275 {0.1289} - -
03-14A-11
Rear Bearing Inner Race Assembly Note
Caution
• Press in until the force required suddenly increases.
• Install the spacer selected for the pinion height adjustment, confirm that the installation direction
is correct.
1. Press the rear bearing inner race in using the

SSTs. SPACER
DBG314ZWB053
Drive Pinion Assembly Note

Drive pinion preload adjustment
Caution
• Do not install the oil seal.
1. Assemble the following parts to the drive pinion.

• New collapsible spacer
• Front bearing
• New spacer
• Companion flange
• New washer
• New locknut
2, Turn the serrated part of the drive pinion by hand to seat the bearing.
3. Tighten the locknut temporarily tightened in Step ,-------::------------------,
1 from the lower limit of the specified tightening
torque using the SST, and obtain the specified
preload. Record the tightening torque at this time ..
Tightening torque
128-284 N·m {13.1-28.9 kgf.m, 94.5-209
ft·lbf}
Front differential drive pinion preload

1.28-1.76 N·m {13.1-17.9 kgf.cm, 11.4-
15.5 in·lbf}
DBG314ZWB016
• If the specified preload cannot be obtained

within the specified tightening torque, replace with a new collapsible spacer and adjust again.
4. Remove the locknut, washer, and companion flange.
03-14A-12
Oil Seal (Companion Flange) Assembly Note
1. Apply differential oil to the lip of a new oil seal.
2. Assemble the oil seal using the SST.
DBG314ZWB071
Locknut Assembly Note

1. Assemble the companion flange and washer.
2. Tighten a new locknut using the SST.
Tightening torque
128-284 N·m {13.1-28.9 kgf·m, 94.5-209
ft.lbf}
Side Bearing Outer Race, Adjusting Screw, Bearing Cap Assembly Note
1. Install the differeritial gear component to the ,----------------------,
carrier. After loosely tightening the bearing outer
race and bearing cap mounting bolts, completely
tighten the adjustment screw by hand. Then,
while turning the ring gear, alternately tighten the
left and right adjustment screws using the SST.
2. Adjust the drive pinion, ring gear backlash and the
side bearing preload as follows:
(1) Mark the ring gear at four points at approx.
90 0 intervals and mount a dial indicator to the
carrier so that the feeler comes in contact at a
90 0 angle with one of the ring gear teeth.
DBG314ZWB045
(2) Turn both bearing adjusters equally until the

backlash becomes 0.09-0.11 mm {0.0035-
0.0043 in} using the SST.
DBG314ZWB046
03-14A-13
(3) Inspect for the backlash at the three other
marked points and make sure that the
minimum backlash is more than 0.05 mm
{0.002 in} and difference of the maximum and
minimum backlash value is less than 0.07
mm {0.0028 in}.
DBG314ZWB019
(4) After adjusting the backlash, tighten the

adjustment screws equally until the distance
between both pilot sections on the bearing
caps (L) become as specified.
Bearing cap bolt tightening torque

73-107 N·m {7.45-10.9 kgf·m, 53.9-78.9
ft·lbf}
Distance L
204.5 mm {8.052 in}
DBG314ZWB047
3. The inspection and adjustment procedure is as

follows: TOOTH MARKING COMPOUND
(1) Coat both surfaces of 6-8 teeth of the ring
gear uniformly with a tooth marking
compound.
(2) While moving the ring gear back and forth by
hand, rotate the drive pinion several times and
inspect the tooth contact.
(3) If the tooth contact is good, wipe off the red
lead coating.
(4) If it is not good, adjust the pinion height, then
adjust the backlash.
CHU0314W020
Toe and flank contact

1. Replace the spacer with a thinner one, and move
the drive pinion outward. TOE CONTACT FLANK CONTACT
CHU0314W021
03-14A-14
Heel and face contact
1. Replace the spacer with a thicker one. Bring the HEEL CONTACT FACE CONTACT
drive pinion inward.
CHU0314W022
Oil Seal (Differential Casing) Assembly Note

1. Tap in the new oil seal to the front differential
casing using the SSTs.
03-14A-1S
DIFFERENTIAL [REAR]
03-148 DIFFERENTIAL [REAR]

REAR DIFFERENTIAL REAR DIFFERENTIAL DISASSEMBLY
LOCATION INDEX ................. 03-14B-1 [STANDARD DIFFERENTIAL] ...... . 03-14B-4
REAR DIFFERENTIAL OIL REAR DIFFERENTIAL ASSEMBLY
INSPECTION . .................... 03-14B-2 [STANDARD DIFFERENTIAL] ...... . 03-14B-7
REAR DIFFERENTIAL OIL REAR DIFFERENTIAL DISASSEMBLY
REPLACEMENT .................. 03-14B-2 [LSD (LIMITED SLIP
REAR DIFFERENTIAL DIFFERENTIAL)] . ................ . 03-14B-16
REMOVAL/INSTALLATION .......... 03-14B-3 REAR DIFFERENTIAL ASSEMBLY
[LSD (LIMITED SLIP
DIFFERENTIAL)] ................. . 03-14B-18
REAR DIFFERENTIAL LOCATION INDEX

dcf031427100wOS
4x2 EXPECT Hi-Rider
Hi-Rider, 4x4
DCF314ZWB006
Rear differential
(See 03-14B-2 REAR DIFFERENTIAL OIL
INSPECTION.)
(See 03-14B-2 REAR DIFFERENTIAL OIL
REPLACEMENT.)
(See 03-14B-3 REAR DIFFERENTIAL REMOVAU
INSTALLATION.)
(See 03-14B-4 REAR DIFFERENTIAL
DISASSEMBLY [STANDARD DIFFERENTIAL].)
(See 03-14B-7 REAR DIFFERENTIAL ASSEMBLY
[STANDARD DIFFERENTIAL].)
(See 03-14B-16 REAR DIFFERENTIAL
DISASSEMBLY [LSD (LIMITED SLIP
DIFFERENTIAL)].)
(See 03-14B-18 REAR DIFFERENTIAL ASSEMBLY
[LSD (LIMITED SLIP DIFFERENTIAL)].)
03-148-1
DIFFERENTIAL [REAR]
REAR DIFFERENTIAL OIL INSPECTION
dcf031427000w03
U
2. Remove the oil-fill plug and the washer.
3. Inspect if the oil level is close to the rim of the oil-
fill plug hole.
• If the oil is not close to the rim of the oil-fill OIL LEVEL PLUG
plug hole, add oil.
~)
4. Install the oil-fill plug with a new washer and
tighten.
Tightening torque
~
39.2-53.9 N·m {4.00-5.49 kgf.m, 29.0-39.7
ft.lbf} WASHER
DBG314ZWB001
REAR DIFFERENTIAL OIL REPLACEMENT

dcf031427000w04
2. Remove the oil-fill plug.
3. Remove the drain plug and drain the oil.
4. Install the drain plug with a new washer and
tighten.
Tightening torque
39.2-53.9 N·m {4.00-5.49 kgf·m, 29.0-39.7
ft·lbf}
5. Add the specified oil through the oil-fill plug hole.
Rear differential oil [STANDARD

DIFFERENTIAL]
DBG314ZWB002
Viscosity: SAE 90
Oil capacity (approx. quantity): 1.3-1.5 L {1.3-1.4 US qt, 1.1-1.2 Imp qt} (WL-3)
Oil capacity (approx. quantity): 2.35-2.55 L {2.23-2.41 US qt, 1.96-2.12 Imp qt} (WL-C)
Rear differential oil [LSD]

Viscosity: SAE 90
Oil capacity (approx. quantity): 2.25-2.45 L {2.13-2.31 US qt, 1.88-2.03 Imp qt}
6. After adding the oil, perform the oil level inspection.

7. Install the oil-fill plug with a new washer and tighten.
Tightening torque
39.2-53.9 N·m {4.00-5.49 kgf·m, 29.0-39.7 ft·lbf}
03-148-2
I,
DIFFERENTIAL [REAR]
REAR DIFFERENTIAL REMOVAL/INSTALLATION
dcf031427100w06
Caution
• Clean away the ole sealant before applying the new sealant.
• Install the differential carrier 10 min. after applying sealant.
• Allow the sealant to set at least 30 min. after installation before filling the differential with the
specified oil.
1. Drain the rear differential oil.

2. Remove the propeller shaft. (See 03-15-2 PROPELLER SHAFT REMOVAUINSTALLATION.)
5. Add rear differential oil. (See 03-148-2 REAR DIFFERENTIAL OIL REPLACEMENT.)
26-28
{2.6-2.9, 19-20}
DCF314ZWB003
Axle shaft and back plate component 2 Rear differential component

(See 03-12-2 AXLE SHAFT REMOVAU (See 03-14A-3 Front Differential, Joint Shaft
INSTALLATION.) Component Removal Note.)
Rear Differential Component Removal Note

1. To prevent the rear differential from dropping,
leave the two bolts loosely tightened, then tap the
rear differential carrier using a wooden hammer.
03-148-3
DIFFERENTIAL [REAR]
REAR DIFFERENTIAL DISASSEMBLY [STANDARD DIFFERENTIAL]
dcf03142710Dw07
Warning
• The engine stand is equipped with a self-lock mechanism, however, if the rear differential is tilted,
the self-lock mechanism could become inoperative. If the rear differential unexpectedly rotates, it
could cause injury, therefore do not maintain the rear differential tilted. When turning the rear
differential, grasp the rotation handle firmly.
9
WITH
REAR ASS
DCF314ZWB004
1 Differential component 14 Adjusting shim

(See 03-14B-5 Differential Component Disassembly 15 Front bearing outer race
Note.) (See 03-14B-7 Front Bearing Outer Race, Rear
2 Bearing cap Bearing Outer Race Disassembly Note.)
(See 03-14B-5 Bearing Cap Disassembly Note.) 16 Oil baffle
3 Adjusting shim 17 Rear bearing outer race
4 Side bearing outer race (See 03-14B-7 Front Bearing Outer Race, Rear
5 Side bearing inner race Bearing Outer Race Disassembly Note.)
(See 03-14B-5 Side Bearing Inner Race 18 Differential carrier
Disassembly Note.) 19 Bolt
6 Locknut 20 Ring gear
(See 03-14B-5 Locknut Disassembly Note.)
21 Knock pin
7 Companion flange (See 03-14B-7 Knock Pin Disassembly Note.)
(See 03-14B-6 Companion Flange Disassembly
22 Pinion shaft
Note.)
23 Thrust block
8 Drive pinion
(See 03-14B-6 Drive Pinion Disassembly Note.) 24 Pinion gear
9 Oil seal 25 Thrust washer
(See 03-14B-6 Oil Seal Disassembly Note.) 26 Side gear
10 Thrust washer 27 Thrust washer
11 Front bearing inner race 28 Differential case
12 Collapsible spacer 29 ABS sensor rotor (with rear ABS)
13 Rear bearing inner race
(See 03-14B-6 Rear Bearing Inner Race
Disassembly Note.)
03-148-4
DIFFERENTIAL [REAR]
Differential Component Disassembly Note
1. Install the differential component to the SSTs.
DBG314ZWB032
Bearing Cap Disassembly Note

1. Place a mark on one of the bearing caps so that
the left and right bearing caps won't get mixed up.
Use the mark for matching at the time if assembly.
Side Bearing Inner Race Disassembly Note
Caution
• Mark the left bearing in order to install in the same position.
1. Remove the side bearing inner race from the gear

case using the SSTs.
Locknut Disassembly Note

1. Hold the companion flange using the SST and
remove the locknut.
DBG314ZWB012
03-148-5
DIFFERENTIAL [REAR]
1. Pull the companion flange out using the SST.
Drive Pinion Disassembly Note

1. Remove the drive pinion by tapping with a plastic
hammer.
2. Remove the drive pinion component by tapping
the locknut lightly using a plastic hammer.
3. Remove the locknut in.stalled in Step 1.

1. Remove the oil seal using a screw driver.
DBG314ZWB007
Rear Bearing Inner Race Disassembly Note
Note
• Mark or otherwise distinguish between the front and rear inner races so that they are not mixed at the time
of reassembly.
1. Remove the rear bearing inner race using the

SST.
03-148-6
DIFFERENTIAL [REAR]
Front Bearing Outer Race, Rear Bearing Outer Race Disassembly Note
Note
•. Mark or otherwise distinguish between the front and rear outer races so that they are not mixed up at the
time of reassembly.
1. Remove the bearing outer race by lightly tapping

the edge of the bearing outer race using a
flathead screwdriver.
DBG314ZWB010
Knock Pin Disassembly Note
Caution
• Insert the bar from the knock pin hole at the opposite side from where the ring gear is installed.
1. Secure the gear case in a vise and remove the

knock pin by using a 4 mm {O.16 in} diameter bar.
DBG314ZWB011
REAR DIFFERENTIAL ASSEMBLY [STANDARD DIFFERENTIAL]

dcf031427100w08
Warning
• The engine stand is equipped with a self-lock mechanism, however, if the rear differential is tilted,
the self-lock mechanism could become inoperative. If the rear differential unexpectedly rotates, it
could cause injury, therefore do not maintain the rear differential tilted. When turning the rear
differential, grasp the rotation handle firmly.
Note
• Clean away the old silicone sealant before applying the new silicone sealant.
• Install the rear cover within 10 min after applying the silicone sealant.
• Allow the sealant to set at least 30 min or more after installation before filling the differential with
differential oil.
03-148-7
1 DIFFEREN
. Assemble in the orde' . TIAL [REAR]
r Indicated in th e t able
75 95 .
1m
mm
____N_.m{.kgt.m, tt-lbf}
Adjusting shim DCF314ZWB005

Differential case
(See 03-14B-11 Ad·justlng
R . Shi A
(Sear bearing inner rae m ssembly Note.)
ee03-14B-13
Note.} e
Rear Bearing Inner RaceAsse bl
19 .
Dnve pinion m y
(See 03-14B-13 D .nve p ..
Collapsible spacer Inion Assembly Note.)
Front bearing inner race

Thrust was-;::-h-er--=-~
23 Oil seal
(See 03-14B-14 Oil S
24 Companion flange eal Assembly Note.}
25 Locknut
(See
S.d 03-14B-14 Locknut Ass b
( ~
26
e bearing outer rac em Iy Note.)
ee 03-14B-14 S. e
_1_3_,Differential carrier
27 Adjusting Shl~
Shim, Bearin C Ide Bearing Outer R .
ap Assembly Note.) ace, Adjusting
14 Oil baffle (See 03-14B-14 S·Ide Bearing 0

Shim ,B . Cap
eanng A uter Race Ad· .
15 (See 03-14B-10 Oil Baffle A
F~ont bearing outer rac ssembly Note [WL-C] )
(
28 Bearing cap ssembly Note.) , Jus,,"g
ee 03-14B-1 0 F e · (See03-14B-14 . A Bearin g 0 uter Race Ad· .
Assembly Note.} ront Bearing Outer Race Shim , Beanng Side
. Cap ssembly Note.) ,justlng
16 Rear bearing
(See 03-14B- f~ter race
Assembly Note.) Rear Bearing Outer Race
03-148-8
DIFFERENTIAL [REAR]
Thrust Washer Assembly Note
1. Adjust the backlash of the side gear$ and pinion gear as follows:
(1) Set a dial gauge to the pinion gear as shown ,..----------------------,
/ in the figure.
(2) Secure one of the side gears.
(3) Move the pinion gear and measure the
backlash at the end of the pinion gear.
Backlash of side gear and pinion gear

0-0.1 mm {0-0.004 in}
(4) If the backlash exceeds the standard, use the

thrust washers to adjust.
Knock Pin Assembly Note

1. Assemble the side gears, thrust washer, thrust
block, pinion gears, pinion shaft and knock pin.
After assembling the knock pin, make a crimp so
that the pin will not come out of the gear case.
Ring Gear Assembly Note

1. Coat the ring gear and gear case facing surfaces with locking agent.
2. Install the ring gear and tighten the bolt to the specified torque.
Side Bearing Inner Race Assembly Note
Caution
• Bearings should be assembled to the original positions.
1. Press the side bearings into the gear case using

the SST.
DBG314ZWB041
03-148-9
DIFFERENTIAL [REAR]
Oil Baffle Assembly Note [WL-C]
1. Tap the oil baffle into the differential carrier using
the SSTs.
DBG314ZWB058
Front Bearing Outer Race Assembly Note

1. Press the front bearing outer race into the carrier
DBG314ZWB059
Rear Bearing Outer Race Assembly Note

WL-3
1. Press the rear bearing outer race into the differential carrier using the SSTs and a press.
DBG314ZWB043
WL-C
1. Press the rear bearing outer race into the
differential carrier using the SSTs and a press.
0...",..",..
DBG314ZWB060
03-148-10
DIFFERENTIAL [REAR]
Adjusting Shim Assembly Note
Pinion height adjustment [WL-3]
Note
1. Assemble the spacer, rear bearing inner race and

SST (49 UN27 004) on to the SST (49 8531 565).
Secure the collar with the O-ring, then install this ~. I I I :
to the carrier.
UN27 003), companion flange, washer and nut to
the SST (49 8531 565).
SPACER
REAR BEARING
FRONT BEARING

dial indicator to zero.
5. Place the SST (49 U027 008) on top of the SST
570) on top of the SST (49 U027 008).
A6A63192026
6. Place the measuring probe of the dial indicator so
that it contacts the place where the side bearing is
installed in the carrier, then measure left and right
side of the lower position.
DBG314ZWB073
measurements taken in Step 6 and then divide
the total by 2. From this sum, subtract the sum of
®
t
the number inscribed on the end of the drive ...........J-~*---O
pinion divided by 100. (If there is no figure t
inscribed, use 0.) This is the pinion height e
adjustment value.
Note
• When the values obtained by the
measurements taken in Step 7 are 0.06 mm
{00.003 in}, 0.04 mm {0.002 in} and the tip
DBG314ZWB049
surface of the drive pinion value is 2, the
formula is ((0.06+0.04)/2)-(2/100)=0.03.
Therefore, assemble a spacer 0.03 mm {0.001 in} thicker than the currently assembled one.
03-148-11
DIFFERENTIAL [REAR]
Pinion height adjustment [WL-C]
Note

SST (49 U027 015) on to the SST (49 8531 565).
Secure the collar with the O-ring, then install this
to the carrier.
E027 007), companion flange, washer and nut to
the SST (49 8531 565). SPACER
8531 565) can be turned by hand. REAR BEARING
ORI
FRONT BEARING
DBG314ZWB069

5. Place the SST (491361 555) on top of the SST
570) on top of the SST (49 1361 555).
A6A63192026

the number inscribed on the end of the drive
inscribed, use 0.)
DBG314ZWB048
8. Subtract 3 from measurement taken in Step 7.

This is the pinion height adjustment value.
®
Note ........,./-~.....---O+
• When the values obtained by the +
measurements taken in Step 7 and 8 are 8
3.06 mm {0.1205 in}, 3.04 mm {0.1197 in}
and the tip surface of the drive pinion value
is 2, the formula is ((3.06+3.04)/2)-(2/100)- { ..
3=0.03. Therefore, assemble a spacer 0.03
mm {0.001 in} thicker than the currently
assembled one.
DBG314ZWB049
03-148-12
DIFFERENTIAL [REAR]
Rear Bearing Inner Race Assembly Note
Caution
• Press in until the force required suddenly increases.
• Install the spacer selected for the pinion height adjustment, confirm that the installation direction
is correct.
1. Press the rear bearing inner race using the SST.

WL-3 SPACER
WL-C

Caution

• Front bearing
• New spacer
• New washer
• New locknut
2. Adjust the preload of the drive pinion bearing as follows:
(1) Turn the companion flange by hand to seat the bearing.
(2) Use a torque wrench to tighten the locknut ,--------:=:---,------------------,
temporarily tightened in step 1, and confirm
that the specified preload can be obtained
within the specified tightening torque range.
The torque applied at this time will be used
after the oil seal is installed.
Tightening torque
298-500 N·m {30.4-50.9 kgf·m, 220-368
ft.lbf}
Rear differential drive pinion preload

DBG314ZWB016
WL-3: 2.0-3.5 N·m {21-35 kgf·cm, 18-30
in.lbf}
WL-C, WE-C: 2.55-4.00 N·m {26.1-40.7 kgf·cm, 22.6-35.4 in·lbf}
(3) If the specified preload can't be obtained within the specified tightening torque range, replace the
collapsible spacer and inspect again.
(4) Remove the locknut, washer and companion flange.
03-148-13
DIFFERENTIAL [REAR]
Oil Seal Assembly Note
1. Apply differential oil to the lip of a new oil seal.
2. Press the oil seal in until it touches the end of the
differential carrier using the SST.
WL-3
WL-C
DBG314ZWB017
Locknut Assembly Note

1. Assemble the companion flange and washer.
2. Tighten the new locknut using the SST.
3. Verify that the preload is within the specification.

WL-3: 2.0-3.5 N·m {21-35 kgf·cm, 18-30
in.lbf}
WL-C, WE-C: 2.55-4.00 N'm {26.1-40.7 kgf·cm,
22.6-35.4 in·lbf}
DBG314ZWB018
Side Bearing Outer Race, Adjusting Shim, Bearing Cap Assembly Note
Ring gear backlash adjustment
1. Install the gear case component on the differential carrier.
2. Push the gear case component tot he left side of the differential carrier and measure the clearance between the
side bearing and differential carrier. This measurement is the left and right total shim thickness.
3. Divide the amount of shim in step 2 appropriately between the right and left side, then install the bearing cap.
4. Adjust the drive pinion, ring gear backlash and the side bearing preload as follows:
(1) Mark the ring gear at four points at approx. ,----------------;-;-------,
90° intervals and mount a dial indicator to the
carrier so that the feeler comes in contact at
90° angle with one of the ring gear teeth.
5. Inspect the backlash at the three other marked
pOints and make sure that the minimum backlash
is more than 0.05 mm {0.002 in} and difference
of the maximum and minimum backlash value is
less than 0.03 mm {0.001 in}.
Ring gear backlash

0.12-0.20 mm {0.005-0.007 in}
6. If backlash is not as specified, correct the

backlash by switching whims from one side of the
differential case to the other.
7. Using a torque wrench, inspect the total rotating
torque of the pinion three complete revolutions,
and then reading the rotating torque. The
readings should not exceed 2.4 N·m {24.0
kgf.cm, 20.8 in·lbf}. If the backlash is within r
specification but the rotating torque is to high, the
preload may be adjusted by removing an equal
amount of shims from both sides of the
differential.
A6A63192036
03-148-14
DIFFERENTIAL [REAR]
8. The inspection and adjustment procedure is as follows:
(1) Coat both surfaces of 6-8 teeth of the ring r--------------------,
gear uniformly with a tooth marking Ivl"r~"'I"'\.:1 COMPOUND
compound.
(2) While moving the ring gear back and forth by
hand, rotate the drive pinion several times and
inspect the tooth contact.
(3) If the tooth contact is good, wipe off the red
lead coating.
(4) If it is not good, adjust the pinion height, then
adjust the backlash.
CHU0314W020
Toe and flank contact

1. Replace the spacer with a thinner one, and move
TOE CONTACT FLANK CONTACT
the drive pinion outward.
Heel and face contact

1. Replace the spacer with a thicker one. Bring the HEEL CONTACT FACE CONTACT
drive pinon inward.
CHU0314W022
03-148-15
DIFFERENTIAL [REAR]
REAR DIFFERENTIAL DISASSEMBLY [LSD (LIMITED SLIP DIFFERENTIAL)]
dcf031427101w01
DBG314ZWB020
1 Differential component 14 Adjusting shim

(See 03-14B-5 Differential Component Disassembly 15 Front bearing outer race
Note.) (See 03-14B-7 Front Bearing Outer Race, Rear
2 Bearing cap Bearing Outer Race Disassembly Note)
(See 03-14B-5 Bearing Cap Disassembly Note) 16 Oil baffle
3 Adjusting shim 17 Rear bearing outer race
4 Side bearing outer race 18 Differential carrier
5 Side bearing inner race 19 Bolt
(See 03-14B-5 Side Bearing Inner Race
20 Ring gear
Disassembly Note)
21 Knock pin
6 Locknut
(See 03-14B-7 Knock Pin Disassembly Note)
(See 03-14B-5 Locknut Disassembly Note)
22 Pinion shaft
7 Companion flange
(See 03-14B-6 Companion Flange Disassembly 23 Thrust block
Note) 24 Limited slip differential component
8 Drive pinion (See 03-14B-17 Limited Slip Differential Component
(See 03-14B-6 Drive Pinion Disassembly Note) Disassembly Note.)
9 Oil seal 25 Pinion gear thrust washer
(See 03-14B-6 Oil Seal Disassembly Note) 26 Pinion gear
10 Thrust washer 27 Side gear
(See 03-14B-6 Oil Seal Disassembly Note)
28 Side gear thrust washer
11 Front bearing inner race LSD clutches
29
12 Collapsible spacer Differential case
30
13 Rear bearing inner race
(See 03-14B-6 Rear Bearing Inner Race
Disassembly Note)
03-148-16
DIFFERENTIAL [REAR]
Limited Slip Differential Component Disassembly Note
1. Place one of the axle shafts, which was removed ,------------------------,
from the component, into a vise, with the splines
extending above the jaws of the vise far enough to
component. Position the differential case onto the
axle shaft as a holding fixture by aligning the
splines of the side gear with those of the axle
shaft.
DBG314ZWB021
2. Install the SST into the bottom of the side gear,

and apply grease to the centering hole of it.
3. Install the SSTs into the differential case.
DBG314ZWB023
4. Tighten the SSTs to move the side gears away

from the pinion gears and relieve the normal
loaded condition.
5. Push out the thrust washers located behind the
pinion gears.
6. Momentarily loosen the SST. Retighten the SST
until a very slight movement of the pinion gears is
seen.
03-148-17
DIFFERENTIAL [REAR]
7. Insert SST into the bore of the pinion shaft and
rotate the differential case until the pinion gears
can be removed through the large openings in the
differential case.
DBG314ZWB025
8. Retain the top side gear and clutch pack in the

differential case by hand and remove the SSTs.
9. Remove the top side gear and clutch pack. Keep
the stack of the clutch plates and clutch discs in
exact order.
10. Remove the retainer clips from both clutch packs DIFFERENTIAL
to allow separation of the clutch discs and clutch CLUTCH PACK
plates for cleaning and inspection.
DBG314ZWB026
REAR DIFFERENTIAL ASSEMBLY [LSD (LIMITED SLIP DIFFERENTIAL)]

dcf031427101w02
Note
• Clean away the old sealant before applying the new sealant.
• Install the rear cover within 10 minutes after applying sealant.
• Allow the sealant to set at least 30 minutes after installation before filling the differential with the specified
oil.

75-95
{7.6-9.7,
55-70}
iii 130-150
gZJ {13.2-15.3,
~ 96-110}
iii
~
I
15 mJ
iii
5 iii mJ
6 mJ
mJ -,.....-.. 7
iii
298-500
I mJ
{30.3-50.9,
220-368}
__
DBG314ZWB027
~__tD_i_ffe_r_en_t_ia_lc_a_se______________________~1 ~ 34-+I_s·_ld_e~g_ea_r_th_r_us_t_w_a_sh_e_r________________~
2 . LSD clutches . . . Side gear
03-148-18
DIFFERENTIAL [REAR]
5 Pinion gear 18 Adjusting shim

6 Pinion gear thrust washer (See 03-14B-19 Adjusting Shim Assembly Note.)
7 Limited slip differential component 19 Rear bearing inner race
(See 03-14B-21 Limited Slip Differential Component (See 03-14B-13 Rear Bearing Inner Race Assembly
Assembly Note.) Note.)
8 Thrust block 20 Drive pinion
(See 03-14B-20 Drive Pinion Assembly Note.)
9 Pinion shaft
21 Collapsible spacer
10 Knock pin
(See 03-14B-9 Knock Pin Assembly Note.) 22 Front bearing inner race
11 Ring gear 23 Thrust washer
(See 03-14B-9 Ring Gear Assembly Note.) 24 Oil seal
12 Bolt (See 03-14B-10 Oil Baffle Assembly Note [WL-C].)
13 Side bearing inner race 25 Companion flange
(See 03-14B-9 Side Bearing Inner Race Assembly 26 Locknut
Note.) (See 03-14B-14 Locknut Assembly Note.)
14 Differential carrier 27 Side bearing outer race
15 Oil baffle (See 03-14B-14 Side Bearing Outer Race, Adjusting
(See 03-14B-10 Oil Baffle Assembly Note [WL-C].) Shim, Bearing Cap Assembly Note.)
16 Front bearing outer race 28 Adjusting shim
(See 03-14B-1 0 Front Bearing Outer Race (See 03-14B-14 Side Bearing Outer Race, Adjusting
Assembly Note.) Shim, Bearing Cap Assembly Note.)
17 Rear bearing outer race 29 Bearing cap
(See 03-14B-1 0 Rear Bearing Outer Race (See 03-14B-14 Side Bearing Outer Race, Adjusting
Assembly Note.) Shim, Bearing Cap Assembly Note.)
Adjusting Shim Assembly Note

Pinion height adjustment
Note

SST (49 U027 015) on to the SST (49 8531 565).
Secure the collar with the O-ring, then install this
to the carrier.
E027 007), companion flange, washer and nut to
the SST (49 8531 565).
3. Tighten the nut to the extent that the SST (49 SPACER
REAR BEARING
o RING
FRONT BEARING
DBG314ZWB070
03-148-19
DIFFERENTIAL [REAR]
5. Place the SST (491361 555) on top of the SST
570) on top of the SST (49 1361 555).
A6A63192026

7. Add the 1wo (left and right) values obtained by the
the number inscribed on the end of the drive
inscribed, use 0.)
8. Subtract 3 from measurement taken in Step 7.

This is the pinion height adjustment value.
®
Note ........,J-~~--O+
• When the values obtained by the
measurements taken in Step 7 and 8 are e+
3.06 mm {0.1205 in}, 3.04 mm {0.1197 in}
and the tip surface of the drive pinion value
is 2, the formula is ((3.06+3.04)/2)-(2/100)-
3=0.03. Therefore, assemble a spacer 0.03
mm {0.001 in} thicker than the currently
assembled one.
DBG314ZWB049

Caution

• Front bearing
• New spacer
• New washer
• New locknut
2. Adjust the preload of the drive pinion bearing as follows:
(1) Turn the companion flange by hand to seat the bearing.
03-148-20
DIFFERENTIAL [REAR]
(2) Usea torque wrench to tighten the locknut
temporarily tightened in step 1, and confirm
that the specified preload can be obtained
within the specified tightening torque range.
The torque applied at this time will be used
after the oil seal is installed.
Tightening torque
298-S00 N·m {30.4-S0.9 kgf.m, 220-368
ft.lbf}

DBG314ZWB016
2.SS-4.00 N·m {26.1-40.7 kgf·cm, 22.6-
3S.4 in·lbf}
(3) If the specified preload can't be obtained within the specified tightening torque range, replace the
collapsible spacer and inspect again.
(4) Remove the locknut, washer and companion flange.
Limited Slip Differential Component Assembly Note
Note
• Always replace the entire disc and plate kits, even if only one component requires it.
1. Assemble the retainer clips to the ears of the clutch plates. Make sure both clips are completely assembled or
seated onto the ears of the clutch plates.
2. Place the differential case on a bench. Assemble the clutch pack and side gear into the differential case. Make
sure the clutch pack stays assembled to the splines of side gear, and the retainer clips differential case.
3. Install the SSTs to the differential case.
4. With tools assembled to the differential case,
position the differential case onto the axle shaft by
aligning the splines of the differential side gear
with those of the axle shaft.
5. Position both pinion gears opposite one another
through the openings in the differential case. Align
holes of the differential pinion gears with each
other. Hold the pinion gears by hand.
6. Tighten the SST so the side gears move away
condition.
DBG314ZWB028
7. While holding the pinion gears in place, insert

SST into the hole of pinion shaft in the differential
case. Pull on the SST rotating differential case
allowing the differential pinion gears to rotate and
enter into the differential case.
8. Adjust the SST by very slightly loosening or
tightening until the required load is applied to
allow the side gears and pinion gears to rotate.
9. Rotate the differential case until the holes of both
pinion gears are aligned with those of the
differential case.
DBG314ZWB029
03-148-21
DIFFERENTIAL [REAR]
10. Apply torque to the SST for clearance to
assemble the differential thrust washers.
Note
• During assembly, be sure the holes of the
thrust washers and gears are lined up
exactly with those of the differential case.
DBG314ZWB030
11. Assemble thrust washers into the differential

case. Use a very small screwdriver or shim stock
to push the washers into place.
DBG314ZWB031
'~,.,
03-148-22
PROPELLER SHAFT
03-15 PROPELLER SHAFT

PROPELLER SHAFT PROPELLER SHAFT
LOCATION INDEX ................. 03-15-1 REMOVAUINSTALLATION ......... . 03-15-2
PROPELLER SHAFT INSPECTION .... 03-15-4
PROPELLER SHAFT LOCATION INDEX

dcf031525002w01
4x2
;~'
4x4
2
DBG315ZWB004
Front propeller shaft 2 Rear propeller shaft

(See 03-15-2 PROPELLER SHAFT REMOVAU (See 03-15-2 PROPELLER SHAFT REMOVAU
(See 03-15-4 PROPELLER SHAFT INSPECTION.) (See 03-15-4 PROPELLER SHAFT INSPECTION.)
03-15-1
PROPELLER SHAFT
PROPELLER SHAFT REMOVAL/INSTALLATION
dcf031525002w02
1. Remove the member.

4x2
S15M-D
::~ ~ 98-117
~ru
<::".
{5H9'~~if~
~36-52 P ~36-52
JP {3.7-5.3,27-38}
J {3.7-5.3,27-38}

DBG315ZWB002
1 Nut
2 Nut
3 Propeller shaft
(See 03-15-3 Propeller Shaft Removal Note.)
(See 03-15-3 Propeller Shaft Installation Note.)
4x4
98-117
{10.0-11.9, 72.3-86.2} ~@)
DBG315ZWB003
1 Nut
2 Propeller shaft
3 Nut
4 Nut
5 Propeller shaft
03-15-2
PROPELLER SHAFT
Propeller Shaft Removal Note
Caution
• When replacing with a new propeller shaft, mark the companion flange to match the position of the
tag on the propeller shaft.
1. Before removing the propeller shaft, make alignment marks on the yoke and differential companion flange.
FRONT PROPELLER SHAFT (4x4)
/ DBG315ZWB007
REAR PROPELLER SHAFT
MARKING
DBG315ZWB001
2. Install the SST to the extension housing. (R15M-

D)
DBG511AWB013
Propeller Shaft Installation Note

1. Align the marks and install the propeller shaft.
2. When installing a new propeller shaft, align the differential companion flange mark with the tag on the propeller
shaft and assemble.
03-15-3
PROPELLER SHAFT
FRONT PROPELLER SHAFT (4x4)
/ DBG315ZWB007
REAR PROPELLER SHAFT
MARKING
DBG315ZWB001
PROPELLER SHAFT INSPECTION

dcf031525002w03
1. Use a dial gauge to measure the runout of the

propeller shaft at each position.
replace the propeller shaft.
Propeller shaft maximum runout

0.4 mm {0.016 in} MEASURE MEASURE MEASURE
KJOd@
POSITION POSITION POSITION
DBG315ZWB005
2. Inspect the play and rotation of the joint by turning

the universal joint in the direction shown by the
arrow.
Propeller shaft initial torque (Reference value)

0.29-1.76 N·m {3.0-17.9 kgf·cm, 2.6-15.5
in·lbf}
• If there is excessive play or initial torque,

( ,
DBG315ZWB006
03-15-4
PROPELLER SHAFT [SAT]
03-15 PROPELLER SHAFT [SAT]

PROPELLER SHAFT LOCATION INDEX PROPELLER SHAFT
[SAT] ........................... 03-15-1 REMOVAL/INSTALLATION [SAT] .... . 03-15-2
PROPELLER SHAFT INSPECTION
[SAT] ............................ 03-15-6
PROPELLER SHAFT LOCATION INDEX [SAT]

id0315b38001 00
4x2
absggw00000989
Front propeller shaft 2 Rear propeller shaft

(See 03-15-2 PROPELLER SHAFT REMOVAU (See 03-15-2 PROPELLER SHAFT REMOVAU
INSTALLATION [5ATJ.) INSTALLATION [5AT].)
(See 03-15-6 PROPELLER SHAFT INSPECTION (See 03-15-6 PROPELLER SHAFT INSPECTION
[5ATJ·) [5ATJ·)
03-15-1
PROPELLER SHAFT REMOVAUINSTALLATION [SAT]
id0315b3800300
1. Remove the member.
4x2
@)
@
"®36-S2
{3.7-S.3,27-38}
absggw00000990
3 Propeller shaft
INut (See 03-15-4 Propeller Shaft Removal Note.)
2 Nut
03-15-2
4x4
98-117
{10.Q-11.9, 72.3-86.2} ~
!J
~
49-58
{5.0-5.9, 37-42}
1
1 Nut 4 Nut
2 Front propeller shaft 5 Rear propeller shaft
(See 03-15-4 Propeller Shaft Removal Note.) (See 03-15-4 Propeller Shaft Removal Note.)
(See 03-15-5 Propeller Shaft Installation Note.) (See 03-15-5 Propeller Shaft Installation Note.)
3 Nut
03-15-3
Propeller Shaft Removal Note
Caution
• When replacing with a new propeller shaft, mark the companion flange to match the position of the
tag on the propeller shaft.
1. Before removing the propeller shaft, make alignment marks on the yoke and differential or transfer companion
flange.
Front propeller shaft (4x4)
FRONT DIFFERENTIAL SIDE
o C
~-4='~~
__'!=--1";"~
'-- MARKING
absggw00000995

TRANSFER SIDE
REAR DIFFERENTIAL SIDE
MARKING
absggw00001021
03-15-4
Propeller Shaft Installation Note
1. Align the marks and install the propeller shaft.
2. When installing a new propeller shaft, align the differential or transfer companion flange mark with the tag on
the propeller shaft and assemble.
Front propeller shaft (4x4)
FRONT DIFFERENTIAL SIDE
REAR DIFFERENTIAL SIDE
MARKING
absggw00001021
03-15-5
PROPELLER SHAFT INSPECTION [5AT]
id0315b3800500
Front Propeller Shaft (4x4) Inspection

replace the propeller shaft. MEASURE
POSITION
Front propeller shaft maximum runout
0.4 mm {0.016 in}
absggw00001007
Rear Propeller Shaft (4x2,4x4) Inspection

replace the propeller shaft. MEASURE MEASURE MEASURE
POSITION POSITION POSITION
Rear propeller shaft maximum runout
0.4 mm {O.016 in}
~D[j@
absggw00001003
2. Inspect the play and rotation of the joint by turning

the universal joint in the direction shown by the
arrow.
Rear propeller shaft initial torque (Reference

value)
0.29-1.76 N·m {3.0-17.9 kgf·cm, 2.6-15.5
in·lbf}
• If there is excessive play or initial torque,

absggw00001004
03-15-6
TRANSFER
03-16 TRANSFER
TRANSFER LOCATION INDEX ....... 03-16-1 VEHICLE SPEED SENSOR (VSS)
TRANSFER OIL INSPECTION ........ 03-16-1 REMOVAUINSTALLATION
TRANSFER OIL REPLACEMENT ..... 03-16-2 [S15MX-D] ....................... 03-16-2
VEHICLE SPEED SENSOR (VSS)
INSPECTION [S15MX-D] ........... 03-16-2
TRANSFER LOCATION INDEX

dcf03160000Ow01
DBG316ZWB003
1 Transfer oil 3 Transmission and transfer

(See03-16-1 TRANSFER OIL INSPECTION.) (See 05-11 8-1 0 TRANSMISSION AND TRANSFER
(See03-16-2 TRANSFER OIL REPLACEMENT.) REMOVAUINSTALLATION [S15MX-D].)
2 Vehicle speed sensor (See 05-118-12 INSPECTION AFTER
(See 03-16-2 VEHICLE SPEED SENSOR (VSS) TRANSMISSION AND TRANSFER INSTALLATION
REMOVAUINSTALLATION [S15MX-D].) [S15MX-D].)
(See 03-16-2 VEHICLE SPEED SENSOR (VSS)
INSPECTION [S15MX-D].)
TRANSFER OIL INSPECTION

dcf031617001w01
1. Park the vehicle on level ground.

2. Remove the filler plug and with the packing.
3. Verify that the oil is near the brim of the plug port.
• If the oil level is low, add the specified amount
and type of oil through the filler plug hole.
Transfer oil
Type: Mercon® Multi-purpose AFT XT-2-QDX
4. Tighten the filler plug with a new packing.
Tightening torque
39-59 N·m {4.0-6.0 kgf·m, 29-43 ft·lbf}
DBG316ZWB001
03-16-1
TRANSFER
TRANSFER OIL REPLACEMENT
dcf031617001w02
1. Park the vehicle on level ground.

2. Remove the transfer under cover. (See 05-118-10 TRANSMISSION AND TRANSFER REMOVAU
INSTALLATION [S15MX-D].)
3. Remove the drain plug with the packing.
4. Drain the oil into a suitable container.
5. Tighten the drain plug with a new packing. FILLER PLUG
Tightening torque
39-59 N·m {4.0-S.0 kgf·m, 29-43 ft.lbf}
6. Remove the filler plug with the packing and add
the specified amount and type of oil through the
filler plug hole until the level reaches the bottom of
the filler plug hole.
DRAIN PLUG
Transfer oil
DBG316ZWB002
Capacity (approximate quantity): 1.85 L
{1.95 US qt, 1.S3 Imp qt}
7. Tighten the filler plug with a new packing.

Tightening torque
39-59 N·m {4.0-S.0 kgf·m, 29-43 ft·lbf}
8. Install the transfer under cover. (See 05-118-10 TRANSMISSION AND TRANSFER REMOVAU
INSTALLATION [S15MX-D].)
VEHICLE SPEED SENSOR (VSS) REMOVAL/INSTALLATION [S15MX-D]

dcf031600000w02
Caution
• Water or foreign material entering the connector can cause a poor connection or corrosion. Be
sure not to drop water or foreign material on the connector when disconnecting it.
2. Disconnect the VSS connector.
3. Remove the VSS.
4. Apply the specified oil to a new O-ring and install
it on a VSS.
5. Install the VSS.
Tightening torque
7.8-11.0 N·m {80-112 kgf·cm, 70-97
in·lbf}
6. Connect the VSS connector.

DBG316ZWB005
VEHICLE SPEED SENSOR (VSS) INSPECTION [S15MX-D]
dcf031600000w03
1. Remove the VSS. (See 03-16-2 VEHICLE SPEED SENSOR (VSS) REMOVAUINSTALLATION [S15MX-D].)
2. Measure voltage between terminals of the VSS
while the gear is turning.
Vehicle speed sensor (VSS) voltage [S15MX-
D]
5 V or less @ill)
• If the voltage is within the specification, the
VSS is normal. Repair the related wiring
harness.
• If the voltage is not within the specification
(tester needle does not move), replace the
I~~I
VSS.
DBG316ZWB006
3. Install the VSS. (See 03-16-2 VEHICLE SPEED
SENSOR (VSS) REMOVAUINSTALLATION
[S15MX-D].)
03-16-2
TRANSFER [SRSSS]
03-16 TRANSFER [5R55S]

TRANSFER LOCATION INDEX SPEED SENSOR REMOVAUINSTALLATION
[5R55S] ......................... 03-16-1 [5R55S] . ........................ . 03-16-4
TRANSFER CASE OIL INSPECTION MOTOR INSPECTION [5R55S] ....... . 03-16-4
[5R55S] ......................... 03-16-2 MOTOR REMOVAUINSTALLATION
TRANSFER CASE OIL REPLACEMENT [5R55S] . ......................... 03-16-5
[5R55S] ......................... 03-16-2 CLUTCH COIL INSPECTION [5R55S] ... 03-16-6
SPEED SENSOR INSPECTION TRANSFER CASE REMOVAUINSTALLATION
[5R55S] ......................... 03-16-3 [5R55S] . ........................ . 03-16-7
TRANSFER LOCATION INDEX [5R55S]

id0316c1800100
1 Transfer case oil 3 Speed sensor

(See 03-16-2 TRANSFER CASE OIL INSPECTION (See 03-16-3 SPEED SENSOR INSPECTION
[5R55S].) [5R55S].)
(See 03-16-2 TRANSFER CASE OIL (See 03-16-4 SPEED SENSOR REMOVAU
REPLACEMENT [5R55S].) INSTALLATION [5R55S].)
2 Motor 4 Clutch coil
(See 03-16-4 MOTOR INSPECTION [5R55S].) (See 03-16-6 CLUTCH COIL INSPECTION
(See 03-16-5 MOTOR REMOVAUINSTALLATION [5R55S].)
[5R55S].) 5 Transfer case
(See 03-16-7 TRANSFER CASE REMOVAU
INSTALLATION [5R55S].)
03-16-1
TRANSFER [5R55S]
TRANSFER CASE OIL INSPECTION [5R55S]
id0316c1816200
1. Warm up the transfer case.
Caution
• Do not use an impact wrench when removing the filler plug. It may damage the transfer case.
2. Remove the filler plug from the transfer case.

• If the oil level is low, add the specified amount
and type of oil through the filler plug hole.
Transfer case oil

Type: Mercon® V
4. Tighten the new filler plug.
Tightening torque
19-30 N·m {2.0-3.0 kgf.m, 15-22 ft.lbf}
TRANSFER CASE OIL REPLACEMENT [5R55S]

id0316c1816300
1. Warm up the transfer case.
2. Remove the transfer case under cover. (See 05-13-45 AUTOMATIC TRANSMISSION REMOVAU
Caution
• Do not use an impact wrench when removing the filler plug or drain plug. It may damage the
transfer case.
3. Remove the drain plug from the transfer case.

4. Drain the oil into a suitable container.
5. Tighten the new drain plug.
Tightening torque
19-30 N·m {2.0-3.0 kgf.m, 15-22 ft.lbf}
6. Remove the filler plug and add the specified

amount and type of oil through the filler plug hole
until the level reaches the bottom of the filler plug
·hole.
arnffw00001909
Transfer case oil
Type: Mercon® V
Capacity (approx. quantity): 1.2 L {1.3 US qt, 1.1 Imp qt}
7. Tighten the new filler plug.
Tightening torque
19-30 N·m {2.0-3.0 kgf.m, 15-22 ft·lbf}
8. Install the transfer case under cover. (See 05-13-45 AUTOMATIC TRANSMISSION REMOVAUINSTALLATION
[5R55S].)
03-16-2
TRANSFER [5R55S]
SPEED SENSOR INSPECTION [5R55S]
id0316c1816000
Caution
• Water or foreign material entering the connector can cause poor connections or corrosion. Be
sure that water or foreign material do not enter the connector when disconnecting it.

2. Remove the transfer case under cover. (See 05-13-45 AUTOMATIC TRANSMISSION REMOVAL!
3. Disconnect the speed sensor connector.
Caution
• Do not apply a shock in the speed
sensor.
• Do not damage the terminals.
SPEED SENSOR
arnffw00001910
4. Measure the resistance between the speed

sensor terminals A and B.
• If there is any malfunction, replace the speed
sensor. (See 05-13-29 TURBINE SHAFT
SPEED (TSS) SENSOR REMOVAU
Transfer case speed sensor resistance

Approx. 300 ohms
5. Connect the speed sensor connector.

6. Install the transfer case under cover. (See 05-13-
arnffw00001911
45 AUTOMATIC TRANSMISSION REMOVAU
03-16-3
TRANSFER [5R55S]
SPEED SENSOR REMOVAUINSTALLATION [5R55S]
id0316c1815700
Caution
• Do not damage the speed sensor.

3. Remove in the order indicated in the table. 8-11 N·m {82-112 kgf·cm,
1 Connector (wiring harness-side) 71-97 in·lbf}
2 Connector (part side)

3 Connector cover
4 Clutch coil terminal
5 Speed sensor bracket
6 Wiring harness bracket
7 Speed sensor
4. Install in the reverse order of removal. 7
arnffw00001914
MOTOR INSPECTION [5R55S]

id0316c1815900
Motor Operating Inspection
Caution

3. Remove the motor. (See 03-16-5 MOTOR REMOVAUINSTALLATION [5R55S].)
Caution
• Do not apply a shock in the speed sensor.
4. Connect battery positive voltage to motor terminal

F, connect terminal C to ground, and then verify
that the motor operates as shown in the table.
5. Connect battery positive voltage to motor terminal
C, connect terminal F to ground, and then verify
that the motor operates as shown in the table.
• If the operation condition is not normal,
replace the motor. (See 03-16-5 MOTOR
REMOVAUINSTALLATION [5R55S].)
Terminal
Motor position
C F
Ground B+ 2H~4H~4L arnffw00001912
B+ Ground 4L~4H~2H
6. Measure the resistance between the motor terminals C and F.

• If there is any malfunction, replace the motor. (See 03-16-5 MOTOR REMOVAUINSTALLATION [5R55S].)
Transfer case motor resistance

approx. 117 ohms
03-16-4
TRANSFER [5R55S]
7. Install the motor. (See 03-16-5 MOTOR REMOVAUINSTALLATION [5R55S].)
[5R55S].)
Motor Position Inspection

3. Measure the resistance between the motor
terminals
• If there is any malfunction, replace the motor.
(See 03-16-5 MOTOR REMOVAU
0-0 : Continuity
Terminal
Motor position
A B 0 E G
2H 0 '-" D arnffwOOOO 1912
4H 0 D--- f-O
4L 0 "'-" D
arnffw00001913
[5R55S].)
MOTOR REMOVAUINSTALLATION [SRSSS]

id0316c1815800
Caution
• Do not damage the motor.

1 Speed sensor connector
2 Connector
3 Speed sensor bracket
4 Motor
arnffw00001915
03-16-5
TRANSFER [5R55S]
CLUTCH COIL INSPECTION [5R55S] .
id0316c1816100
Caution

3. Disconnect the speed sensor connector.
Caution
• Do not apply a shock in the speed
sensor.
Cl
SPEED SENSOR ~
CONNECTOR· -'"
arnffw00001910
4. Measure the resistance between the speed

sensor terminal C and body ground.
• If there is any malfunction, replace the clutch
coil.
Transfer case clutch coil resistance

Approx. 3 ohms
5. Connect the speed sensor connector.

6. Install the transfer case under cover. (See 05-13-
45 AUTOMATIC TRANSMISSION REMOVAU
arnffw00001911
03-16-6
TRANSFER [5R55S]
TRANSFER CASE REMOVAL/INSTALLATION [5R55S]
id0316c1816400

3. Remove the oxidation catalytic converter (See 01-15-1 EXHAUST SYSTEM REMOVAUINSTALLATION [WL-C,
WE-C (RANGER (AT))].)
4. Remove the propeller shaft. (See 03-15-2 PROPELLER SHAFT REMOVAUINSTALLATION [5AT].)
5. Remove the crossmember and transmission mount rubber. (See 05-13-45 AUTOMATIC TRANSMISSION
REMOVAUINSTALLATION [5R55S])
6. Lower the transmission slightly.
38.0-52.0 N·m
{3.9-5.3 kgf·m,
28.1-38.3 ft.lbf}
arnffw00001916
1 Speed sensor connector 4 Bolt

2 Motor connector 5 Bracket
3 Breather hose 6 Transfer case
03-16-7
4-WHEEL DRIVE
03-18 4-WHEEL DRIVE

4-WHEEL DRIVE LOCATION INDEX ... 03-18-1 RFW ACTUATOR INSPECTION ........ 03-18-5
4x4 INDICATOR SWITCH JOINT SHAFT COMPONENT
INSPECTION .................... 03-18-2 REMOVAL/INSTALLATION ......... . 03-18-5
TRANSFER NEUTRAL SWITCH JOINT SHAFT COMPONENT
INSPECTION . .................... 03-18-2 DISASSEMBLY ••..•.••..........• . 03-18-7
RFW SWITCH INSPECTION .......... 03-18-3 JOINT SHAFT COMPONENT
RFW MAIN SWITCH ASSEMBLy ...................... 03-18-9
REMOVAL/INSTALLATION . ......... 03-18-3 CONTROL BOX
RFW MAIN SWITCH INSPECTION ..... 03-18-4 REMOVAL/INSTALLATION .......... 03-18-12
ONE-WAY CHECK VALVE CONTROL BOX
INSPECTION . ................... 03-18-4 DiSASSEMBLy/ASSEMBLy ......... 03-18-13
LOCK AND FREE SOLENOID SHIFT FORK INSPECTION ........... 03-18-14
VALVES INSPECTION ............. 03-18-4
4-WHEEL DRIVE LOCATION INDEX

dcf03182730Ow01
DBG318ZWB040
1 4x4 indicator switch 6 Lock and free solenoid valve

(See 03-18-2 4x41NDICATOR SWITCH (See 03-18-4 LOCK AND FREE SOLENOID
INSPECTION.) VALVES INSPECTION.)
2 Transfer neutral switch 7 RFWactuator
(See 03-18-2 TRANSFER NEUTRAL SWITCH (See 03-18-5 RFW ACTUATOR INSPECTION.)
INSPECTION.) 8 PCM (RFW control)
3 RFW switch (See 01-40B-10 PCM INSPECTION [WL-C, WE-C].)
(See 03-18-3 RFW SWITCH INSPECTION.) 9 Joint shaft component
4 RFW main switch (See 03-18-5 JOINT SHAFT COMPONENT
(See 03-18-3 RFW MAIN SWITCH REMOVAU REMOVAUINSTALLATION.)
INSTALLATION.) (See 03-18-7 JOINT SHAFT COMPONENT
(See 03-18-4 RFW MAIN SWITCH INSPECTION.) DISASSEMBLY.)
5 One-way check valve (See 03-18-9 JOINT SHAFT COMPONENT
(See 03-18-4 ONE-WAY CHECK VALVE ASSEMBLY.)
INSPECTION. )
03-18-1
4-WHEEL DRIVE
10 Control box
(See 03-18-12 CONTROL BOX REMOVAU
INSTALLATION.)
(See 03-18-13 CONTROL BOX DISASSEMBLY/
ASSEMBLY.)
(See 03-18-14 SHIFT FORK INSPECTION.)
4x4 INDICATOR SWITCH INSPECTION

dcf031827461w01
1. Jack up the vehicle and support it on safety stands.
2. Remove the 4x4 indicator switch.
3. Inspect for continuity between the terminals as
shown using a tester.
• If not correct, replace the 4x4 indicator switch.
Continuity Switch
Yes Depressed (ON)
No Released (OFF)
DBG318ZWB001
4. Install the 4x4 indicator switch.
Tightening torque
25-34 N·m {2.6-3.4 kgf·m, 19-25 ft.lbf}
12 mm {O.472 in}
13 mm {O.512 in}
DBG318ZWB002
TRANSFER NEUTRAL SWITCH INSPECTION

dcf031827462w01
2. Remove the transfer neutral switch.
3. Inspect for continuity at the switch using a tester.
• If not correct, replace the transfer neutral
switch.
Continuity Switch
Yes Depressed (ON)
No Released (OFF)
4. Install the transfer neutral switch.
Tightening torque
25-34 N·m {2.6-3.4 kgf·m, 19-25 ft.lbf}
12 mm {O.472 in}
13 mm {O.512 in}
DBG318ZWB004
03-18-2
4-WHEEL DRIVE
RFW SWITCH INSPECTION
dcf031827463wO 1

2. Remove the RFW switch.
3. Inspect for continuity at the switch using a tester.
• If not correct, replace the RFW switch.
Continuity Switch
Yes Depressed (ON)
No Released (OFF)
--
DBG318ZWB005
4. Install the RFW switch.
Tightening torque
24.5-34.3 N·m {2.50-3.49 kgf.m, 18.1-25.2
tt·lbf}
OFF
12 mm {0.472 in}
13 mm {O.512 in}
RFW MAIN SWITCH REMOVAUINSTALLATION

1. Remove the lower panel. (See 09-17-10 LOWER PANEL REMOVAUINSTALLATION.)
IGonnector
DBG318ZWB039
03-18-3
4-WHEEL DRIVE
RFW MAIN SWITCH INSPECTION
dcf031827464w02
1. Remove the RFW main switch.

2. Inspect for continuity between the terminals as
shown using a tester.
0-0 : Continuity r'f1"1 ,--, !"It

Terminal I 1><1 I
BIE
Switch
A B C D
!@..
0 ~ -0 D B
DEPRESSED
0 -0
!@..
RELEASED 0 ~ -0
DBG318ZWB007
• If not correct, replace the switch. DBG318ZWB008
ONE-WAY CHECK VALVE INSPECTION

dcf031813995wOl
1. Remove the one-way check valve.

2. Blow through A and inspect that air flows from B.
3. Blow through B and inspect that air does not flow
B A
from A.
• If not correct, replace the one-way check
valve. ONE-WAY CHECK VALVE
DBG318ZWB009
LOCK AND FREE SOLENOID VALVES INSPECTION

dcf031827740wOl
1. Disconnect the vacuum hoses and the connector from each solenoid valve.
2. Blow through each valve from port B. ,..---'-'- - - - - - - - - - - - - - - - - - ,
3. Inspect that air flows from the air filter. BLOW
4. Connect 12 V and a ground to the terminals of B •
each valve.
5. Blow through each valve from port B.
AIR FILTER
DBG318ZWB010
6. Inspect that air flows from port A.

• If not correct, replace the lock and free
solenoid valve(s).
AIR FILTER
DBG318ZWBOll
03-18-4
4-WHEEL DRIVE
RFW ACTUATOR INSPECTION
dcf03182731Ow01

2. Disconnect the vacuum hoses from the actuator.
3. Connect a vacuum pump tester to the actuator (free side) as shown.
4. Apply 26.66 kPa {200 mmHg, 7.87 inHg} ,---------------------,
vacuum, and verify that the rod moves toward the
left.
5. Disconnect the vacuum pump tester.
6. Connect the vacuum pump tester tot he actuator
(lock side) as shown.
DBG318ZWB012
7. Apply 26.66 kPa {200 mmHg, 7.87 inHg}

vacuum, and inspect that the rod moves toward
the right.
• If not correct, replace the RFW actuator.
JOINT SHAFT COMPONENT REMOVAL/INSTALLATION

dcf031827300w02
1. Drain the front differential oil.

4. Add the front differential oil. (See 03-14A-2 FRONT DIFFERENTIAL OIL REPLACEMENT.)
03-18-5
4-WHEEL DRIVE
43.1-60.8
{4.4D-6.19,
31.8-44.8}
36.3-53.9
{3.71-5.49,26.8-39.7}
DBG318ZWB014
1 Drive shaft 4 Snap pin

(See 03-13-2 FRONT DRIVE SHAFT REMOVAU 5 Joint shaft component, control box component
INSTALLATION. )
6 Gear sleeve
2 Vacuum hose
7 Output shaft
3 RFW switch connector (See 03-18-6 Output Shaft Removal Note.)
Output Shaft Removal Note

1. Remove the output shaft using the SST.
DBG318ZWB015
03-18-6
4-WHEEL DRIVE
JOINT SHAFT COMPONENT DISASSEMBLY
dcf031827300w03
1. Disassemble in the order indicated in the table
1Q Imil
3
Imil
DBG318ZWB016
1 Control box 8 Dust seal

2 Clip 9 Bearing
3 Remote freewheel hub (See 03-18-8 Bearing Disassembly Note.)
(See03-18-7 Remote Freewheel Hub Disassembly 10 Oil seal
Note.) (See 03-18-8 Oil Seal Disassembly Note.)
4 Spacer 11 Joint shaft
5 Retaining ring 12 Needle bearing
6 Ball bearing 13 Clip
(See 03-18-8 Ball Bearing Disassembly Note.) 14 Casing
7 Adjusting shim(s}
Remote Freewheel Hub Disassembly Note

1. Remove the remote freewheel hub using the SST.
" I
DBG318ZWB017
03-18-7
4-WHEEL DRIVE
Ball Bearing Disassembly Note
1. Remove the ball bearing and the joint shaft using
a press.
DBG318ZWB018
2. Remove the ball bearing using a press.
DBG318ZWB019
Bearing Disassembly Note

1. Remove the dust seal and bearing using the SST
and a suitable bar.
DBG318ZWB020

1. Remove the oil seal using the SST.
DBG318ZWB021
03-18-8
4-WHEEL DRIVE
JOINT SHAFT COMPONENT ASSEMBLY
dcf031827300w04
9
mJ
DBG318ZWB023
1 Casing 7 Retaining ring

2 Oil seal 8 Spacer
(See 03-18-10 Oil Seal Assembly Note.) (See 03-18-11 Spacer, Remote Freewheel Hub
3 Adjustment shim(s) Assembly Note.)
(See 03-18-10 Adjustment Shim(s), Ball Bearing 9 Remote freewheel hub
Assembly Note.) (See 03-18-11 Spacer, Remote Freewheel Hub
4 Ball bearing Assembly Note.)
(See 03-18-10 Adjustment Shim(s), Ball Bearing 10 Clip
Assembly Note.) 11 Dust seal
5 Joint shaft (See 03-18-11 Dust Seal Assembly Note.)
(See 03-18-10 Joint Shaft Assembly Note.) 12 Needle bearing
6 Bearing 13 Clip
(See 03-18-11 Bearing Assembly Note.)
14 Control box
03-18-9
4-WHEEL DRIVE
1. Apply differential oil to a new oil seal.
2. Install the new oil seal using the SST and a press.
~. I I I •
DBG318ZWB024
Adjustment Shim(s), Ball Bearing Assembly Note

1. Install the removed shim(s) and the ball bearing
PLATE
2. Install a new retaining ring.
DBG318ZWB025
3. Measure the clearance between the ball bearing

and the retaining ring.
• If not as specified, adjust by adding or
removing shims, Use no more than two shims
on either side.
Maximum clearance
0.15 mm {0.0059 in}
Available shim thickness

0.15 mm {0.0059 in}
0.30 mm {0.0118 in} DBG318ZWB026
0.35 mm {0.0138 in}

0040 mm {0.0157 in}
0.50 mm {0.0197 in}
Joint Shaft Assembly Note

1. Install the joint shaft using the SST and a press.
II.
DBG318ZWB027
03-18-10
4-WHEEL DRIVE
Bearing Assembly Note
1. Install the bearing using the SSTs and a press.
DBG318ZWB028
Spacer, Remote Freewheel Hub Assembly Note

1. Install the removed spacer and the remote
freewheel hub using a suitable pipe and the SST
and a press.
2. Install a new clip.
3. Measure the clearance between the remote

freewheel hub and the clip.
• If not as specified, adjust by adding or
removing spacers. Use no more than two
spacers on either side.
Maximum clearance
0.15 mm {0.0059 in}
Available shim thickness

0.15 mm {0.0059 in}
0.30 mm {0.0118 in} DBG318ZWB030
0.35 mm {0.0138 in}

0040 mm {0.0157 in}
0.50 mm {0.0197 in}
Dust Seal Assembly Note

1. Install the new dust seal using the SST and a
press.
J. II
DBG318ZWB031
03-18-11
4-WHEEL DRIVE
CONTROL BOX REMOVAUINSTALLATION
dcf031827750w01
1. Drain the front differential oil into a container.

4. Add the specified front differential oil.
1 Vacuum hose
2 RFW switch connector 22.6-26.4
{2.31-2.69,16.7-19.4}
3 Control box
15.7-22.5
{1.61-2.29,
11.6-16.5}
DBG318ZWB032
03-18-12
4-WHEEL DRIVE
CONTROL BOX DISASSEMBLY/ASSEMBLY
dcf03182775Ow02
7m
iii
DBG318ZWB033
1 Snap ring 8 Roll pin

2 Washer (See 03-18-13 Roll Pin Disassembly Note.)
(See 03-18-14 Roll Pin Assembly Note.)
3 RFW actuator
9 Change rod
4 RFW switch and washer
10 Shift fork
5 Spring cap
11 Boot
6 Spring and ball
(See 03-18-14 Boot Assembly Note.)
7 Washer
12 Oil seal
(See 03-18-14 Oil Seal Assembly Note.)
13 Control box
Roll Pin Disassembly Note

1. Remove the roll pin as shown in the figure.
DBG318ZWB034
03-18-13
4-WHEEL DRIVE
1. Assemble a new oil seal using the SST and a
press.
,. I II
DBG318ZWB035
Boot Assembly Note

1. Assemble the boot as shown in the figure.
DBG318ZWB036
Roll Pin Assembly Note

1. Install a new roll pin as shown in the figure.
DBG318ZWB037
SHIFT FORK INSPECTION

dcf031827300w05
1. Measure the clearance between the gear sleeve

and the shift fork.
Standard clearance
0.1-0.4 mm {0.0040-0.0157 in}
Maximum clearance
0.50 mm {0.0197 in}
2. Inspect the output shaft and gear sleeve of the

splines for damage and wear.
• If not correct, replace the output shaft and
gear sleeve as necessary.
DBG318ZWB038
03-18-14
4-WHEEL DRIVE
03-18 4-WHEEL DRIVE

4-WHEEL DRIVE LOCATION INDEX 4x4 CONTROL MODULE INSPECTION
[AT (5R55S)] ..................... 03-18-1 [AT (5R55S)] . .................... . 03-18-3
4x4 SWITCH INSPECTION 4x4 CONTROL MODULE
[AT (5R55S)] ..................... 03-18-2 REMOVAL/INSTALLATION
4x4 SWITCH REMOVAL/INSTALLATION [AT (5R55S)] . .................... . 03-18-5
[AT (5R55S)] ..................... 03-18-3
4-WHEEL DRIVE LOCATION INDEX [AT (5R55S)]

id0318008005d2
arnffw00001888
1 Motor. component 5 4x4 switch

(See 03-16-4 MOTOR INSPECTION [5R55S].) (See 03-18-2 4x4 SWITCH INSPECTION [AT
(See 03-16-5 MOTOR REMOVAUINSTALLATION (5R55S)].)
[5R55S].) (See 03-18-3 4x4 SWITCH REMOVAU
2 Speed sensor INSTALLATION [AT (5R55S)].)
(See 03-16-3 SPEED SENSOR INSPECTION 6 4x4 control module
[5R55S].) (See 03-18-3 4x4 CONTROL MODULE
(See 03-16-4 SPEED SENSOR REMOVAU INSPECTION [AT (5R55S)].)
INSTALLATION [5R55S].) (See 03-18-5 4x4 CONTROL MODULE REMOVAU
3 Clutch coil INSTALLATION [AT (5R55S)].)
(See 03-16-6 CLUTCH COIL INSPECTION 7 Lock and free solenoid valve
[5R55S].) 8 One-way check valve
4 Digital TR sensor 9 Joint shaft component
(See 05-13-20 DIGITAL TRANSMISSION RANGE
(TR) SENSOR INSPECTION [5R55S].) 10 Control box
(See 05-13-22 DIGITAL TRANSMISSION RANGE 11 RFW actuator
(TR) SENSOR REMOVAUINSTALLATION
[5R55S].)
03-18-1
4-WHEEL DRIVE.
4x4 SWITCH INSPECTION [AT (5R55S)]

id0318008050d2
Caution

2. Remove the boot panel.
3. Verify that the continuity is as indicated in the
table.
E C A
F D B
0-0 : Continuity
Connector terminal
Position
A D C F
2H ( )
4H 0 iJ
4L 0- -Q
arnffw00001882
• If there is any malfunction, replace the 4x4

switch. (See 03-18-3 4x4 SWITCH
REMOVAL/INSTALLATION [AT (5R55S)].)
4. Install the boot panel.
0-0 : Continuity
Connector terminal
A B
arnffw00001883
03-18-2
4-WHEEL DRIVE
4x4 SWITCH REMOVAUINSTALLATION [AT (SRSSS)]
id0318008051 d2

2. Remove the boot panel. (See .)
Iknob
2 4x4 sWitch
4x4 CONTROL MODULE INSPECTION [AT (SRSSS)]

id0318008049d2
1. Remove the lower panel.

3. Attach the tester lead to the control module connector and inspect the voltage and continuity according to the
Terminal Voltage Table (Reference).
Terminal Voltage Table (Reference)
n n I ....... 3
1 n n
y w u S Q 0 M K I G E C A
Z X V T R P N L J H F D B
I~~ I arnffw00001875
Terminal Signal name Connected to condition Voltage (V) Inspection item(s)

Motor operating Below 1.0 • Inspect related wiring
Motor control (4L- Motor component harness
A 4H-2H) (shift motor) Motor not operating B+ • Motor component (shift
motor)
Motor control (4L- Motor component harness
B
4H-2H) (shift motor) Motor not operating B+ • Motor component (shift
motor)
Motor control (2H- Motor component harness
C 4H-4L) (shift motor) Motor not operating B+ • Motor component (shift
motor)
03-18-3
4-WHEEL DRIVE

Motor control (2H- Motor component harness
D
4H-4L) (shift motor) Motor not operating B+ • Motor component (shift
motor)
N position Below 1.0 • Inspect related wiring
E Neutral signal Digital TR sensor harness
Except N position Approx.4.3
• Digital TR sensor
4H or 4L mode
2H or 4H position B+ • Inspect related wiring
F 4x4 switch harness
signal 4L position Below 1.0
• 4x4 switch
2H or4H mode
2H position Below 1.0 • Inspect related wiring
G 4x4 switch harness
signal 4H or 4L position B+
• 4x4 switch
2H position Approx.5.0 • Inspect related wiring
Motor component 4H position Approx.5.0 harness
H Position 4
(position sensor)
4L position Approx.4.2
• Motor component
(position sensor)
I Position 2
(position sensor)
• Motor component
(position sensor)
4H position Approx.5.0 harness
J Position 1 Motor component
4L position Below 1.0
• Motor component
(position sensor)
K - - - - -
L Position 3
(position sensor)
• Motor component
(position sensor)
Engine switch OFF Below 1.0 • Inspect related wiring
M Vehicle speed Speed sensor harness
Engine switch ON Approx.5.0
• Speed sensor
Speed sensor or harness
N Ground
motor component Engine switch ON Approx.5.0 • Speed sensor
• Motor component
0 - - - - -
P - - - - -
Q DTC output
Data link connector Engine switch OFF Below 1.0 • Inspect related wiring
(DLC) Engine switch ON Approx.5.0 harness
4x4 indicator light
B+ • Inspect related wiring
OFF harness
R 4x4 indicator light 4x4 indicator light
4x4 indicator light
Below 1.0
• 4x4 indicator light
ON
4L indicator light
S 4L indicator light 4L indicator light OFF harness
4L indicator light ON Below 1.0 • 4L indicator light
T IG 1 Engine fuse harness
Engine switch ON B+
• Engine fuse
, Clutch coil operating B+ • Inspect related wiring
U Clutch coil Clutch coil Clutch coil not harness
Below 1.0 • Clutch coil
operating
Lock solenoid valve
Below 1.0 • Inspect related wiring
operating harness
V Lock solenoid valve Lock solenoid valve
Lock solenoid valve
B+
• Lock solenoid valve
not operating
• Inspect related wiring
W Ground Body ground Under any condition Below 1.0 harness
(W-ground)
03-18-4
4-WHEEL DRIVE

• Inspect related wiring
X Ground Body ground Under any condition Below 1.0 harness
(X-ground)
y B+ PTC/AT fuse
Engine switch OFF
Engine switch ON harness
Z B+ PTC/ATfuse
Engine switch OFF
Engine switch ON harness
4x4 CONTROL MODULE REMOVAUINSTALLATION [AT (5R55S)]

id0318008048d2

2. Remove the lower paneL
4. Install in the reverse order of removaL
18.6-25.5 N·m
{1.90-2.60 kgf·m.
13.8-18.8 ft·lbf}
7.8-10.8 N·m {80-110 kgf·cm. 70-95 in·lbf}

arnffw00001874
IConnector 3 IBracket
2 4x4CM
03-18-5
TECHNICAL DATA

DRIVELINEIAXLE TECHNICAL DATA ~. 03-50-1
DRIVELINEIAXLE TECHNICAL DATA

dcf035000000w02
LH: 507.8-517.8 mm {20.00-20.38 in}

Front drive shaft standard length
RH: 596.7-606.7 mm {23.50-23.88 in}
Viscosity (above -18°C): SAE 90
Front differential oil Viscosity (below -18°C): SAE 80
Oil capacity (approx. quantity): 1.8-2.0 L {2.0-2.1 US qt, 1.6-1.7
Imp qt}

Viscosity: SAE 90
Oil capacity (approx. quantity): 1.3-1.5 L {1.3-1.4 US qt, 1.1-1.2
Rear differential oil [STANDARD DIFFERENTIAL]
Imp qt} (WL-3)
Oil capacity (approx. quantity): 2.35-2.55 L {2.23-2.41 US qt,
1.96-2.12 Imp qt} (WL-C)
Viscosity: SAE 90
Rear differential oil [LSD]
Oil capacity (approx. quantity): 2.25-2.45 L {2.13-2.31 US qt,
1.88-2.03 Imp qt}

Capacity (approximate quantity): 1.85 L {1.95 US qt, 1.63 Imp qt}
Type: Mercon® V
03-50-1
SERVICE TOOLS
03-60 SERVICE TOOLS

DRIVELINEIAXLE SST ... ........... 03-60-1
DRIVELINE/AXLE SST
dcf03600000Ow02
1: Mazda SST number

Example
1 :49 UN30 3050
2:303-050
Engine lifting
brackets
1:49 T028 3AO 1:49 G019 017 1:49 G030 797

2:- 2:- 2:-
Ball joint puller Oil seal installer Handle

set
1 :49 8033 107 1:49 F027 007 1 :49 8033 106

2:- 2:- 2:-
Oil seal installer Attachment for Oil seal installer

072
1:49 H033 101 1:49 B025 001 1 :49 F019 001

2:- 2:- 2:-
Bearing Body Oil seal

remover installerg
1 :498120 645A 1:49 0603 635A 1:498120710

2:- 2:- 2:-
Rear shaft Rear sahft nut Coupling flange

holder wrench holder
1:49 0839 425C 1:49 8026 2A 1 1 :49 0107 680A

2:- ~ 2:- 2:-
~
Bearing puller Rear axle shaft ~ ~ Engine stand
set bearing puller
set
~~~~;;;;;2;;;;;8
03-60-1
SERVICE TOOLS
1 :49 M005 561 1 :49 F027 004 1:49 S120 748

2:- 2:- 2:-
Differential Attachment for Attachment
carrier hunger 080
1:498531 565 1:49 0660 555 1 :49 0727 570

2:- 2:- 2:-
Drive pinion
model
~ /n Gauge block Pinion height
gauge body
®®O~
1:49 H027 002 1:49 UB71 525 1:49 F027 009
e
2:- 2:- 2:-
Bearing Bearing installer Attachment for

remover 068&77
1:49 F027 004 1:49 F027 003 1 :49 U027 008

2:- 2:- 2:-
Attachment for Handle Gauge block

080
1 :49 UN27 004 1 :49 UN27 003 1 :49 F401 331 ..

-::'~~-; ,
®
2:- 2:- 2:-
~
Collar B Collar A Body
1 :49 U027 009 1 :49 U027 013 1:49 U027 014

2:- 2:- 2:-
Oil seal installer
B Attachment B
~
Bolt
1:49 U027 012 1:49 U027 011 1 :49 G030 796

2:- 2:- 2:-
Attachment A
@ Shaft
~
Oil seal installer
~
1 :49 F401 337A 1 :49 U027 007 1 :49 8531 567
2:- 2:- 2:-
Attachment C Oil seal installer Collar A

(ID
03-60-2
SERVICE TOOLS
1:498531 568 1:49 0259 720 1:49 0710 520
(@)
2:- 2:- 0 2:-
Collar B Side bearing Bearing puller

adjustment
wrench
1:49 U027 005 1:49 U027 004 1:49 U027 006

2:- 2:- 2:-
Bearing installer Oil seal remover Bearing installer
1:49 W027 001 1:49 M005 796 1:49 G033 102

2:- 2:- 2:-
Body
@ Body Handle
~
1:49 F026 103 1:49 W010 1:49 0026 102
E:J
2:- 107A 2:-
Wheel hub c::=:::=J 2:-

Sensor rotor
puller Oil seal installer installer
~
1:49 G019 011 1:49 F026 102 1:491011748
2:- 2:- 2:-
~~d
Bearing installer Bearing installer Attachment
1 :49 G033 105 1:49 W033 101 1:49 T019 001
g
2:- 2:- 2:-
~
Attachment Body Attachment
1:49 1361 555 1:49 J027 002 1:49 E027 007

2:- 2:- 2:-
Gauge block Collar Collar
1:490727415 1:49 UN20 4069 1: 49 UN20

2:- 2:204-069 500180
2:205-0018
Bearing installer Remover
Attachment
03-60-3
SERVICE TOOLS
1: 49 UN20 1: 49 F401 331 1: 49 U027 010

500020 2:- 2:-
2:205-0002
Body Bearing installer
Remover
1:498120440 . W08
2:-
Mainshaft
holder
03-60-4
BRAKES
ON-BOARD DIAGNOSTIC GENERAL PROCEDURES .... 04-10

[REAR ANTI LOCK BRAKE CONVENTIONAL
SYSTEM (ABS)] ... . . . . . . . 04-02A BRAKE SYSTEM .......... 04-11
ON-BOARD DIAGNOSTIC PARKING BRAKE SYSTEM ... 04-12
[4-WHEEL ANTI LOCK BRAKE ANTILOCK BRAKE SYSTEM
SYSTEM (4W-ABS)] ....... 04-02B [REAR ANTI LOCK BRAKE
SYMPTOM SYSTEM (ABS)] ........... 04-13A
TROUBLESHOOTING ANTI LOCK BRAKE SYSTEM
[REAR ANTILOCK [4-WHEEL ANTILOCK BRAKE
BRAKE SYSTEM (ABS)] ... 04-03A SYSTEM (4W-ABS)] ........ 04-13B
SYMPTOM TECHNICAL DATA .......... 04-50
TROUBLESHOOTING SERVICE TOOLS ........... 04-60
[4-WHEEL ANTILOCK
BRAKE SYSTEM
(4W-ABS)] ............... 04-03B
04-02A-1
04-02B ON-BOARD DIAGNOSTIC [4-WHEEL ANTILOCK

ABS SYSTEM WIRING DIAGRAM DTC Cl186 [4W-ABS] .............. . 04-02B-12
[4W-ABS] . ............. " ........ 04-02B-l DTC Cl194, Cl198, C1202, C1206,
ON-BOARD DIAGNOSIS [4W-ABS] . ... 04-02B-2 C1210, C1214 [4W-ABS] ., ......... . 04-02B-13
DTC B1317, B1318 [4W-ABS] ........ 04-02B-7 DTC C1222 [4W-ABS] .............. . 04-02B-14
DTC B1342 [4W-ABS] . .... '" ....... 04-02B-8 DTC C1233, C1234, C1235, C1236
DTC B1484 [4W-ABS] ... ............ 04-02B-8 [4W-ABS] ............ , .......... . 04-02B-16
DTC Cl095, Cl096 [4W-ABS] ........ 04-02B-9 DTC C1414 [4W-ABS] .............. . 04-02B-17
DTC Cl145, Cl155, Cl165, Cl175 DTC C1730, C1949, C1950 [4W-ABS] ... 04-02B-18
[4W-ABS] . ....................... 04-02B-ll
ABS SYSTEM WIRING DIAGRAM [4W-ABS]

dcf040200000w15
ABS/SOL20A
Hi-Rider, 4x4
}-----+-OIG SENSOR
ABS40A
BRAKE SWITCH
~~Nt-~~~~~~
BRAKE
LIGHT
ABSWARNING
LIGHT
ABS HU/CM
~~--~~--------~S Q}------{)
INSTRUMENT CLUSTER
ABSWHEEL-
SPEED SENSOR
DCF413BWB001
04-028-1
ON-BOARD DIAGNOSIS [4W-ABS]
dcf040200000w16
On-Board Diagnostic (OBD) Test Description

• The OBD test inspects the integrity and function of the ABS and outputs the results when requested by the
specific tests.
• On-board diagnostic test also:
- Provides a quick inspection of the ABS usually performed at the start of each diagnostic procedure.
- Provides verification after repairs to ensure that no other faults occurred during service.
• The OBD test is divided into 3 tests:
- Read/clear diagnostic results, PID monitor and record and active command modes.
Read/clear diagnostic results

• This function allows you to read or clear DTCs in the ABS HU/CM memory.
PID/Data monitor and record

• This function allows you to access certain data values, input signals, calculated values, and system status
information.
Active command modes

• This function allows you to control devices through the current diagnostic tool.
Reading DTCs Procedure

Using WDS
1. Connect the WDS to the DLC-2 connector.
2. Retrieve DTC using the WDS.
DBR402ZTB003
Using IDS/PDS
1. Connect the IDS/PDS to the DLC-2 connector.
items from the initialization screen of the IDS/
PDS.
2. Select "Self Test".
3. Select "Module".
4. Select "ABS".
2. Select" ABS" .
DBR402ZTB003
3. Verify the DTC according to the directions on the
screen.
4. After completion of repairs, clear all DTCs stored in the ABS HU/CM. (See 04-02B-2 Clearing DTCs
Procedures.)
Clearing DTCs Procedures

Using WDS
1. After repairs have been made, perform the DTCs reading procedure.
2. Erase DTC using the WDS.
3. Ensure that the customer's concern has been resolved.
04-028-2
Using IDS/PDS
1. Connect the 10S/POS to the vehicle OLC-2
connector.
items from the initialization screen of the 10S/
POS .
3. Select "Module".
4. Select "ASS".
DBR402ZTB003
2. Select "ASS".
3. Verify the OTC according to the directions on the screen.
4. Press the clear button on the OTC screen to clear the OTC.
5. Verify that no OTCs are displayed.
PID/Data Monitor and Record Procedure

Using WDS
1. Connect the WOS to the vehicle OLC-2
connector.
2. Access and monitor PIOs using the WOS.
DBR402ZTB003
Using IDS/PDS
1. Connect the 10S/POS to the OLC-2 connector.
POS .
2. Select "OataLogger".
3. Select "Module".
4. Select "ASS".
2. Select "ASS".
DBR402ZTB003
3. Select the applicable PIO from the PIO table.
4. Verify the PIO data according to the directions on the screen.
Note
• The PIO data screen function is used for monitoring the calculated value. Therefore, if the monitored value
of the output parts is not within the specification, inspection of the monitored value of input parts
corresponding to applicable output part control is necessary. In addition, because the system does not
display output part malfunction as abnormality in the monitored value, it is necessary to inspect the output
part individually using a active command modes function.
04-028-3
Active Command Modes Procedure
Using WDS
1. Connect the WDS to the vehicle DLC-2
connector.
2. Turn the engine switch to the ON position (engine
off) or start the engine.
3. Activate active command modes using the WDS.
DBR402ZTB003
Using IDS/PDS
PDS.
1. Select the 'Toolbox" tab.
3. Select "Module".
4. Select "ASS".
2. Select "ASS".
DBR402ZTB003
3. Select the active command modes from the PID
table.
4. Perform the active commands modes, inspect the operations for each parts.
• If there is no operation sound from the relay, motor, and solenoid after the active commands mode
inspection is performed, it is possible that there ia an open or short circuit in the wiring harness, relay, motor
or solenoid, or sticking and operation malfunction.
DTCTable
DTC System malfunction location Page
B1317 Power supply system (See 04-02B-7 DTC B1317, B1318 [4W-ABS].)
B1318 Power supply system (See 04-02B-7 DTC B1317, B1318 [4W-ABS].)
B1342 ABS HUlCM system (See 04-02B-8 DTC B1342 [4W-ABS].)
B1484 Brake switch system (See 04-02B-8 DTC B1484 [4W-ABS].)
C1095 Pump motor, motor relay system (See 04-02B-9 DTC C1095, C1096 [4W-ABS].)
C1096 Pump motor, motor relay system (See 04-02B-9 DTC C1095, C1096 [4W-ABS].)
(See 04-02B-11 DTC C1145, C1155, C1165, C1175
C1145 RF ABS wheel-speed sensor system
[4W-ABS].)
(See 04-02B-11 DTC C1145, C1155, C1165, C1175
C1155 LF ABS wheel-speed sensor system
[4W-ABS].)
(See04-02B-11 DTCC1145, C1155, C1165, C1175
C1165 RR ABS wheel-speed sensor system
[4W-ABS].)
(See 04-02B-11 DTC C1145, C1155, C1165, C1175
C1175 LR ABS wheel-speed sensor system
[4W-ABS].)
C1186 Fail-safe relay system (See 04-02B-12 DTC C1186 [4W-ABS].)
(See 04-02B-13 DTC C1194, C1198, C1202,
C1194 LF outlet solenoid valve system
C1206, C1210, C1214 [4W-ABS].)
(See 04-02B-13 DTC C1194, C1198, C1202,
C1198 LF inlet solenoid valve system
C1206, C1210, C1214 [4W-ABS].)
(See 04-02B-13 DTC C1194, C1198, C1202,
C1202 Rear outlet solenoid valve system
C1206, C1210, C1214 [4W-ABS].)
(See 04-02B-13 DTC C1194, C1198, C1202,
C1206 Rear inlet solenoid valve system
C1206, C1210, C1214 [4W-ABS].)
04-028-4
OTC System malfunction location Page

(See 04-02B-13 OTC C1194, C1198, C1202,
C1210 RF outlet solenoid valve system
C1206, C121 0, C1214 [4W-ABS].)
(See 04-02B-13 OTC C1194, C1198, C1202,
C1214 RF inlet solenoid valve system
C1206, C1210, C1214 [4W-ABS].)
C1222 ABS wheel-speed sensor (slip monitor) system (See 04-02B-14 OTC C1222 [4W-ABS].)
(See 04-02B-16 OTC C1233, C1234, C1235, C1236
C1233 LF ABS wheel-speed sensor/ABS sensor rotor system
[4W-ABS].)
(See 04-02B-16 OTC C1233, C1234, C1235, C1236
C1234 RF ABS wheel-speed sensor/ABS sensor rotor system
[4W-ABS].)
(See 04-02B-16 OTC C1233, C1234, C1235, C1236
C1235 RR ABS wheel-speed sensor/ABS sensor rotor system
[4W-ABS].)
(See 04-02B-16 OTC C1233, C1234, C1235, C1236
C1236 LR ABS wheel-speed sensor/ABS sensor rotor system
[4W-ABS].)
C1414 Incorrect ABS HU/CM installed (See 04-02B-17 OTC C1414 [4W-ABS].)
(See 04-02B-18 OTC C1730, C1949, C1950 [4W-
C1730 * G sensor system
ABS].)
(See 04-02B-18 OTC C1730, C1949, C1950 [4W-
C1949* G sensor system
ABS].)
(See 04-02B-18 OTC C1730, C1949, C1950 [4W-
C1950 * G sensor system
ABS].)
: Hi-Rider, 4x4
PID/DATA Monitor Table

PIO name Operation condition ASS HUlCM
Unit/Condition Action
(definition) (reference) terminal
• ABS warning light is
ABS_LAMP
illuminated: ON
(ABS warning light On/Off Inspect the ABS warning light. S
• ABS warning light is not
driver output state)
illuminated: Off .
ABS_VOLT • Engine switch at ON: Inspect the power supply circuit.
(System battery V Approx. 12.2 V (See 04-13B-5 ABS HU/CM J
voltage value) • Idling: Approx. 14.1 V INSPECTION [4W-ABS].)
• Vehicle is stopped or
driving at a constant
speed: 0 G
ACCLMTR* Inspect the G sensor.
• Cornering to left: Changes
(Forward-G sensor G (See 04-13B-13 G SENSOR P
between 0 G and 1.5 G
input) INSPECTION [4W-ABS].)
• Cornering to right:
Changes between 0 G and
-1.5 G
BOO_ABS • Brake pedal depressed: Inspect the brake switch.
(Brake pedal switch On/Off On (See 04-11-6 BRAKE SWITCH N
input) • Brake pedal released: Off INSPECTION.)
CCNTABS • OTCs detected:
(Number of continuous - 1-255 Perform the OTC inspection. -
codes) • No OTCs detected: 0
Inspect the ABS HU/CM.
PMP_MOTOR • Pump motor activated: On
(See 04-13B-2 ABS HU/CM
(Pump motor output On/Off • Pump motor not activated:
SYSTEM INSPECTION [4W-
-
state) Off
ABS].)
Inspect the ABS HU/CM.
RLY_PMP
(Pump motor relay On/Off • Relay activated: On (See 04-13B-2 ABS HU/CM
-
output state) • Relay not activated: Off SYSTEM INSPECTION [4W-
ABS].)
RLY_VLV • Solenoid valve relay is Inspect ABS HU/CM.

activated: On (See 04-13B-2 ABS HU/CM
(Solenoid valve relay On/Off -
output state) • Solenoid valve relay is SYSTEM INSPECTION [4W-
deactivated: Off ABS].)
V_LF_INL • Solenoid valve activated: Inspect the ABS HU/CM.

On (See 04-13B-2 ABS HU/CM
(Left front inlet solenoid On/Off -
valve output state) • Solenoid valve not SYSTEM INSPECTION [4W-
activated: Off ABS].)
04-028-5
PIO name Operation condition ABS HUlCM

Unit/Condition Action
(definition) (reference) terminal
V_LF_OTL • Solenoid valve activated: Inspect the ABS HU/CM.
(Left front outlet On (See 04-13B-2 ABS HU/CM
On/Off -
solenoid valve output • Solenoid valve not SYSTEM INSPECTION [4W-
state) activated: Off ABS].)
V_RF_INL • Solenoid valve activated: Inspect the ABS HU/CM.
(Right front inlet On (See 04-13B-2 ABS HU/CM
On/Off -
V_RF_OTL • Solenoid valve activated: Inspect the ABS HU/CM.
(Right front outlet On (See 04-13B-2 ABS HU/CM
On/Off -
V_Rear_INL • Solenoid valve activated: Inspect the ABS HUiCM.

On (See 04-13B-2 ABS HU/CM
(Rear inlet solenoid On/Off -
V_Rear_OTL • Solenoid valve activated: Inspect the ABS HU/CM.

On (See 04-13B-2 ABS HUlCM
(Rear outlet solenoid On/Off -
WSPD_LF • Vehicle stopped: 0 KPH, 0

MPH Inspect the ABS wheel-speed
(Left front ABS wheel- KPH,MPH E,F
speed sensor input) • Vehicle running: Vehicle sensor.
speed
WSPD_LR • Vehicle stopped: 0 KPH, 0

(Left rear ABS wheel- KPH,MPH I,G
speed
WSPD_RF • Vehicle stopped: 0 KPH, 0

(Right front ABS wheel- KPH,MPH O,M
speed
WSPD_RR • Vehicle stopped: 0 KPH, 0

(Right rear ABS wheel- KPH,MPH L,K
speed
: Hi-Rider, 4x4
Active Command Modes Table

Operating
Command name Output part Operation
condition
PM P_MOTOR Pump motor
V_LF_INL LF inlet solenoid valve
V_LF_OTL LF outlet solenoid valve
Engine switch at
ON
V_ReacOTL Rear outlet solenoid valve
V_RF_INL RF inlet solenoid valve
V_RF_OTL RF outlet solenoid valve
04··028-6
DTe 81317, 81318 [4W-A8S]
dcf04020000Ow17
DTC B1317, B1318 IPower supply system

• B1317
- The voltage at ABS HUlCM terminal J 16.8 V or more.
DETECTION
CONDITION • B1318
- The vehicle speed exceeds 6 km/h {3.7 mph} and the voltage at ABS HU/CM terminal J is less than
9.6 V.
• ENGINE 15 A fuse malfunction
• Open circuit or short to ground in the wiring harness between the ABS HU/CM terminal J and the
battery
POSSIBLE • Open circuit or faulty ground in the wiring harness between the ABS HUlCM terminal D and the body
CAUSE ground
• Battery deterioration
• Generator malfunction
• Poor connection at connectors (female terminal)
ENGINESW
""
~ -~
ENGINE 15A
0
ABS HU/CM
,.I- @
I
I BATTERY
-'-
ABS HU/CM WIRING HARNESS-SIDE CONNECTOR
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1 INSPECT BATTERY VOLTAGE Yes Make sure that battery terminal connection is normal.
• Is the battery terminal voltage normal? Go to the next step.
No Charge or replace the battery, then go to Step 6.
(See 01-17-4 BATTERY RECHARGING.)
(See 01-17-2 BATTERY REMOVAUINSTALLATION.)
2 INSPECT BATTERY GRAVITY Yes Go to the next step.
• Is battery specific gravity as specified? No Replace the battery, then go to Step 6.
(See 01-17-2 BATTERY REMOVAUINSTALLATION.)
3 INSPECT CHARGING SYSTEM Yes Go to the next step.
• Are the generator and drive belt tensions No Inspect generator and/or drive belt as necessary, then go to
normal? Step 6.
(See 01-10A-3 DRIVE BELT INSPECTION [WL-3].)
(See 01-10B-3 DRIVE BELT INSPECTION [WL-C, WE-C].)
(See 01-17-5 GENERATOR INSPECTION.)
4 INSPECT ABS HUlCM POWER SUPPLY FOR Yes Go to the next step.
OPEN CIRCUIT No Repair or replace the wiring harness for open circuit
• Start the engine. between the ABS HUlCM and ground, then go to Step 6.
• Measure the voltage between ABS HU/CM
terminal J and ground.
• Is the voltage approx. 10 V?
5 INSPECT ABS HUlCM GROUND FOR POOR Yes Go to the next step.
GROUND OR OPEN CIRCUIT No If there is no continuity:
• Turn the engine switch off. • Repair or replace the wiring harness for open circuit
• Measure the resistance between ground and between the ABS HU/CM and ground, then go to the
ABS HU/CM terminal D. next step.
• Is the resistance within 0-1 ohm? If the resistance is not within 0-1 ohm:
• Repair or replace harness for poor ground, then go to
the next step.
04-028-7

6 VERIFY TROUBLESHOOTING COMPLETED Yes Replace the ABS HUlCM, then go to the next step.
• Make sure to reconnect all disconnected (See 04-13B-3 ABS HU/CM REMOVAUINSTALLATION
connectors. [4W-ABS].)
• Clear the DTC from the memory. No Go to the next step.
(See 04-02B-2 Clearing DTCs Procedures.)
• Start the engine and drive the vehicle at 6
kmlh {3.S mph} or more.
• Are any other DTCs present? (See 04-02B-4 DTC Table.)
No DTC troubleshooting completed.
DTC B1342 [4W-ABS]

dcf040200000w18
DTC B1342 lABS HUlCM system

DETECTION
• The ABS HU/CM on-board diagnostic function detects control module malfunction.
CONDITION
POSSIBLE
• ABS HU/CM internal malfunction
CAUSE
1 VERIFY CURRENT STATUS OF Yes Replace the ABS HU/CM, then go to the next step.
MALFUNCTION (See 04-13B-3 ABS HU/CM REMOVAUINSTALLATION
• Clear the DTC from the memory. [4W-ABS].)
(See 04-02B-2 Clearing DTCs Procedures.) No Go to the next step.
DTC B1484 [4W-ABS]

dcf040200000w19
DTC B1484 IBrake switch system

DETECTION
CONDITION • Open circuit in the wiring harness between the ABS HU/CM terminal and the brake switch terminal
POSSIBLE • Brake switch malfunction

CAUSE • Open circuit in the wiring harness between the ABS HU/CM terminal N and the brake switch terminal
BRAKE SWITCH
@; ~~-->-o{A
ABS HU/CM
~ BRAKE LIGHT
!oo
ABS HU/CM WIRING HARNESS-SIDE CONNECTOR BRAKE SWITCH WIRING

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04-028-8
1 INSPECT WIRING HARNESS BETWEEN ABS Yes Go to Step 3.
HUlCM AND BRAKE SWITCH FOR No Go to the next step.
CONTINUITY
• Disconnect the ABS HU/CM connector.
• Is B+ correctly applied to ABS HU/CM
connector terminal N when brake pedal
depressed?
2 INSPECT BRAKE SWITCH Yes Repair or replace the wiring harness for open circuit
• Inspect the brake switch. between ABS HU/CM and brake switch, then go to the next
(See 04-11-6 BRAKE SWITCH step.
INSPECTION.) No Replace the brake switch, then go to the next step.
• Is the brake switch normal? (See 04-11-5 BRAKE SWITCH REMOVAUINSTALLATION.)
3 VERIFY TROUBLESHOOTING COMPLETED Yes Replace the ABS HU/CM, then go to the next step.
• Are the same DTCs present?
• Are any other DTC present? (See 04-02B-4 DTC Table.)
DTC C1095, C1096 [4W-ABS]

dcf040200000w20
DTC C1095, C1096 I

Pump motor, motor relay system
• C1095
- When the pump motor monitor voltage remains at 2.0 V or more for 1 s.
- ABS motor monitor OFF signal is input within specified time limit when the motor signal is switched
DETECTION
from ON to OFF by ABS CM.
CONDITION
• C1096
- When the difference between the battery power supply voltage and pump motor power supply
voltage remains at 4.0 V or more for 0.1 s or more while the pump motor is operating.
• ABS 40 A fus_e malfunction
• Open or short to ground circuit in the wiring harness between the battery and the ABS HUlCM terminal
B
POSSIBLE • Open circuit in the wiring harness between the ABS HU/CM terminal A and the body ground
CAUSE • Open or short circuit in the ABS HU/CM internal motor relay, or stuck motor relay
• Open or short circuit in the ABS HU/CM internal motor, or frozen motor
• Fail-safe relay malfunction
ABS HU/CM
ABS40A
~
B
I-
PUMP
,. MOTOR
I
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04-028-9
1 INSPECT ABS FUSE CONDITION Yes Go to the next step.
• Is the ABS 40A fuse normal? No Replace the fuse, then go to Step 5.
2 INSPECT MOTOR RELAY POWER SUPPLY Yes Go to the next step.
FOR OPEN CIRCUIT No Repair or replace the wiring harness for open circuit
• Turn the engine switch off. between battery positive terminal and ABS HU/CM terminal
• Disconnect ABS HU/CM connector. B, then go to Step 5.
(engine off).
• Measure voltage between ABS HUlCM
terminal B (harness-side) and ground.
3 INSPECT PUMP MOTOR GROUND FOR Yes Go to the next step.
OPEN CIRCUIT No Repair or replace the wiring harness for open circuit
• Turn the engine switch off. between ABS HU/CM terminal A and ground, then go to the
• Inspect for continuity between ABS HU/CM next step.
terminal A (harness-side) and ground.
4 VERIFY PUMP MOTOR OPERATION Yes Go to the next step.
• Turn the engine switch off. No Replace the ABS HU/CM, then go to the next step.
• Connect the current diagnostic tool to the (See 04-13B-3 ABS HU/CM REMOVAUINSTALLATION
DLC-2. [4W-ABS].)
(engine off).
• Access PMP_MOTOR active command
modes using the current diagnostic tool.
• Does the pump motor operate?
5 VERIFY TROUBLESHOOTING COMPLETED Yes Replace the ABS HU/CM, then go to the next step.
km/h {7.S mph} or more.
• Gradually slow down and stop the vehicle.
04-028-10
DTC C1145, C1155, C1165, C1175 [4W-ABS]
dcf04020000Dw21
C1145 RF ABS wheel-speed sensor system

DTC C1155 LF ABS wheel-speed sensor system
C1165 RR ABS wheel-speed sensor system
C1175 LR ABS wheel-speed sensor system
DETECTION • Open circuit or short to ground has been detected in the ASS wheel-speed sensor wiring harness on
CONDITION any of the four vehicle wheels.
• Open circuit or short to ground in the wiring harness between the following ASS HU/CM terminal and
the ASS wheel-speed sensor terminal:
- ASS HUlCM terminal O-RF ASS wheel-speed sensor terminal A
- ASS HU/CM terminal M-RF ASS wheel-speed sensor terminal S
- ASS HU/CM terminal E-LF ASS wheel-speed sensor terminal A
POSSIBLE - ASS HU/CM terminal F-LF ASS wheel-speed sensor terminal S
CAUSE - ASS HUlCM terminal L-RR ASS wheel-speed sensor terminal A
- ASS HU/CM terminal K-RR ASS wheel-speed sensor terminal S
- ASS HU/CM terminal I-LR ASS wheel-speed sensor terminal A
- ASS HU/CM terminal G-LR ASS wheel-speed sensor terminal S
• ASS wheel-speed sensor malfunction
ASS HU/CM
RF
ASS WHEEL-SPEED
SENSOR
LF
ASS WHEEL-SPEED
SENSOR
RR
ASS WHEEL-SPEED
SENSOR
LR
ASS WHEEL-SPEED
SENSOR
ASS WHEEL-SPEED SENSOR WIRING ASS HU/CM WIRING HARNESS-SIDE CONNECTOR

1 INSPECT PID TO VERIFY THAT WHEEL Yes Go to Step 3.
SPEED-SIGNALS ARE TRANSMITTED FROM No Go to the next step.
ABS WHEEL- SPEED SENSOR USING
CURRENT DIAGNOSTIC TOOL
• Connect the current diagnostic tool to the
DLC-2.
• Select the following PIDs using the current
diagnostic tool:
WSPD_LF
WSPD_LR
WSPD_RF
WSPD_RR
• Drive the vehicle.
• Verify that the wheel speed-signals are
transmitted from each ASS wheel-speed
sensor.
• Are the wheel-speed signals transmitted?
04-028-11

2 INSPECT FOR OPEN CIRCUIT IN WIRING Yes Replace the ABS wheel-speed sensor, then go to the next
HARNESS BETWEEN ABS HUlCM AND ABS step.
WHEEL-SPEED SENSOR (See 04-13B-7 FRONT ABS WHEEL-SPEED SENSOR
• Turn the engine switch off. REMOVAUINSTALLATION [4W-ABS (4x2 (EXCEPT Hi-
Rider))].)
• Disconnect the ABS HU/CM connector and (See 04-13B-8 FRONT ABS WHEEL-SPEED SENSOR
ABS wheel-speed sensor.
REMOVAUINSTALLATION [4W-ABS (Hi-Rider, 4x4)).)
• Inspect for continuity in the wiring harness (See 04-13B-10 REAR ABS WHEEL-SPEED SENSOR
between the following ABS wheel-speed
sensor connectors on the vehicle wiring REMOVAUINSTALLATION [4W-ABS (4x2 (EXCEPT Hi-
harness-side and ABS HU/CM connectors. Rider))].)
- RF ABS wheel-speed sensor (+): O-A (See 04-13B-11 REAR ABS WHEEL-SPEED SENSOR
- RF ABS wheel-speed sensor (-): M-B REMOVAUINSTALLATION [4W-ABS (Hi-Rider, 4x4)).)
- LF ABS wheel-speed sensor (+): E-A No Repair or replace the wiring harness, then go to the next
- LF ABS wheel-speed sensor (-): F-B step.
- RR ABS wheel-speed sensor (+): L-A
- RR ABS wheel-speed sensor (-): K-B
- LR ABS wheel-speed sensor (+): I-A
- LR ABS wheel-speed sensor (-): G-B
PRESENT If the malfunction recurs, replace the ABS HU/CM, then go
• Clear the DTCs from the memory. to the next step.
(See 04-02B-2 Clearing DTCs Procedures.) (See 04-13B-3 ABS HU/CM REMOVAUINSTALLATION
• Start the engine and drive the vehicle at 12 [4W-ABS).)
km/h {7.S mph} or more. No Go to the next step.
4 VERIFY THAT NO OTHER DTCS ARE Yes Go to the applicable DTC inspection.
PRESENT (See 04-02B-4 DTC Table.)
• Are any other DTCs output? No DTC troubleshooting completed.
OTC C1186 [4W-ABS]

dcf040200000w23
DTC C1186 I Fail-safe relay system

DETECTION • ABS HU/CM internal valve relay remains OFF when valve relay ON is commanded.
CONDITION • ABS HUlCM internal valve relay remains ON (stuck) when valve relay OFF is commanded.
• ABS/SOL 20 A fuse malfunction
POSSIBLE • Open circuit or short to ground in the wiring harness between the battery and the ABS HU/CM terminal
C
CAUSE
• Open or short circuit in the ABS HUlCM internal valve relay, or stuck valve relay
ABS HU/CM
hr
ABS/SOL 20A
T
-
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BATTERY
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04-028-12
1 INSPECT ABS FUSE CONDITION Yes . Go to the next step.
• Is the ABS/SOL 20 A fuse normal? No Replace the fuse, then go to Step 3.
2 INSPECT VALVE RELAY POWER SUPPLY Yes Go to the next step.
FOR OPEN CIRCUIT No Repair or replace the wiring harness for open circuit
• Turn the engine switch off. between battery positive terminal and ABS HU/CM terminal
• Disconnect ABS HU/CM connector. C, then go to the next step.
(engine off).
• Measure voltage between ABS HUlCM
terminal C (harness-side) and ground.
• Is voltage B+?
3 VERIFY TROUBLESHOOTING COMPLETED Yes Replace the ABS HUlCM, then go to next step.
• Clear the DTC from the memory. (See 04-13B-3 ABS HU/CM REMOVAUINSTALLATION
(See 04-02B-2 Clearing DTCs Procedures.) [4W-ABS].)
• Is the same DTC present? No Go to the next step.
DTC C1194, C1198, C1202, C1206, C1210, C1214 [4W-ABS]

dcf04020000Ow24
C 1194 LF outlet solenoid valve system

C 1198 LF inlet solenoid valve system
C 1202 Rear outlet solenoid valve system
DTC
C 1206 Rear inlet solenoid valve system
C 1210 RF outlet solenoid valve system
II
C 1214 RF inlet solenoid valve system
DETECTION
CONDITION • Solenoid valve operation does not correspond to solenoid ON/OFF commands from the ABS HU/CM.
POSSIBLE • Open or short circuit in the ABS HUlCM internal solenoid valves
CAUSE • Solenoid valve malfunction
1 VERIFY SOLENOID VALVE OPERATION Yes Go to the next step.
• Turn the engine switch off. No Replace the ABS HUlCM, then go to the next step.
• Connect the current diagnostic tool to the (See 04-13B-3 ABS HU/CM REMOVAUINSTALLATION
DLC-2. [4W-ABS].)
(engine off).
• Access the active command mode for the
solenoid valve using the current diagnostic
tool.
• Does the solenoid valve operate?
2 VERIFY DTC TROUBLESHOOTING Yes Repeat the inspection from Step 1.
COMPLETED If the malfunction recurs, replace the ABS HU/CM, then go
• Clear the DTC from the memory. to the next step.
(See 04-02B-2 Clearing DTCs Procedures.) (See 04-13B-3 ABS HU/CM REMOVAUINSTALLATION
• Start the engine and drive the vehicle at 12 [4W-ABS].)
km/h {7.S mph} or more. No Go to the next step.
• Gradually slow down and stop vehicle.
04-028-:13
OTC C1222 [4W-ABS]
dcf04020000OW25
Note
• DTC C1222 will be detected when a malfunctioning ASS wheel-speed sensor cannot be specified.
DTC C1222 ABS wheel-speed sensor (slip monitor) system

DETECTION • Difference between any vehicle wheel speeds exceeds specification when driving at a constant speed.
CONDITION • ASS control operates for 60 s or more.
• ASS wheel-speed sensor malfunction (low output, metal shavings on sensor)
• ASS sensor rotor malfunction (chipping of sensor rotor teeth)
POSSIBLE
• Poor installation of ASS wheel-speed sensor and/or sensor rotor (If the sensor rotor is installed at an
CAUSE
. angle, it may cause output of abnormal wave pattern at high speeds.)
• Excessive clearance between the ASS wheel-speed sensor and sensor rotor
ASS HU/CM
RF
ASS WHEEL-SPEED
SENSOR
LF
ASS WHEEL-SPEED
SENSOR
RR
ASS WHEEL-SPEED
SENSOR
LR
ASS WHEEL-SPEED
SENSOR
ASS WHEEL-SPEED SENSOR WIRING ASS HU/CM WIRING HARNESS-SIDE CONNECTOR

04-028-14
1 INSPECT PID FOR ABNORMAL OUTPUT Yes Go to Step 4.
FROM ABS WHEEL-SPEED SENSOR USING No If there is a difference in speeds of the four wheels, go to the
CURRENT DIAGNOSTIC TOOL next step.
DLC-2.
diagnostic tool:
WSPD_LF
WSPD_LR
WSPD_RF
WSPD_RR
• Start the engine and drive the vehicle.
• Verify that the PIDs ofthe four ABS wheel-
speed sensors correspond approximately.
• Do the vehicle speeds correspond?
2 INSPECT IF MALFUNCTION OCCURRED Yes Go to the next step.
DUE TO IMPROPER SENSOR CLEARANCE No Replace the rear ABS wheel-speed sensor, then go to Step
• Inspect the clearance between the ABS 4.
wheel-speed sensor and the ABS sensor (See 04-13B-7 FRONT ABS WHEEL-SPEED SENSOR
rotor. REMOVAUINSTALLATION [4W-ABS (4x2 (EXCEPT Hi-
Clearance Rider))].)
0.30-1.1 mm {0.012-0.043 in} (See 04-13B-8 FRONT ABS WHEEL-SPEED SENSOR
REMOVAUINSTALLATION [4W-ABS (Hi-Rider, 4x4)].)
(See 04-13B-10 REAR ABS WHEEL-SPEED SENSOR
REMOVAUINSTALLATION [4W-ABS (4x2 (EXCEPT Hi-
Rider))].)
(See 04-13B-11 REAR ABS WHEEL-SPEED SENSOR
3 VISUALLY INSPECT ABS SENSOR ROTOR Yes Go to the next step.
FOR FOREIGN MATERIAL ADHERING OR No Replace the front wheel hub component, front drive shaft or
IMPROPER INSTALLATION rear axle shaft, then go to the next step.
• Is the result normal? (See 03-11-4 WHEEL HUB, STEERING KNUCKLE
REMOVAUINSTALLATION [4x2 (EXCEPT Hi-Rider)].)
(See 03-13-2 FRONT DRIVE SHAFT REMOVAU
INSTALLATION.)
(See 03-12-2 AXLE SHAFT REMOVAUINSTALLATION.)
4 VERIFY DTC TROUBLESHOOTING Yes Repeat the inspection from Step 1.
COMPLETED If the malfunction recurs, replace the ABS HU/CM.
• Make sure to reconnect all disconnected (See 04-13B-3 ABS HUlCM REMOVAUINSTALLATION
km/h {7.S mph} or more.
04-028-15
DTC C1233, C1234, C1235, C1236 [4W-ABS]
dcf04020000Dw26
C1233 LF ABS wheel-speed sensor (short to ground) system

DTC C1234 RF ABS wheel-speed sensor (short to ground) system
C1235 RR ABS wheel-speed sensor (short to ground) system
C1236 LR ABS wheel-speed sensor (short to ground) system
DETECTION • The vehicle wheel speed of any of the four vehicle wheels is 2.75 km/h {1.71 mph} or less when
CONDITION driving at the specified vehicle speed or more.
• Short to ground in the wiring harness between the following ABS HU/CM terminal and the ABS wheel-
speed sensor terminal:
- ABS HU/CM terminal O-RF ABS wheel-speed sensor terminal A
- ABS HU/CM terminal M-RF ABS wheel-speed sensor terminal B
- ABS HU/CM terminal E-LF ABS wheel-speed sensor terminal A
POSSIBLE - ABS HU/CM terminal F-LF ABS wheel-speed sensor terminal B
CAUSE - ABS HU/CM terminal L-RR ABS wheel-speed sensor terminal A
- ABS HU/CM terminal K-RR ABS wheel-speed sensor terminal B
- ABS HU/CM terminall-LR ABS wheel-speed sensor terminal A
- ABS HU/CM terminal G-LR ABS wheel-speed sensor terminal B
• ABS wheel-speed sensor malfunction
ASS HU/CM
RF
ASS WHEEL-SPEED
SENSOR
LF
ASS WHEEL-SPEED
SENSOR
RR
ASS WHEEL-SPEED
SENSOR
LR
ASS WHEEL-SPEED
SENSOR
ABS WHEEL-SPEED SENSOR WIRING ASS HUlCM WIRING HARNESS-SIDE CONNECTOR

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1 INSPECT PID TO VERIFY THAT WHEEL Yes Go to Step 3.
SPEED-SIGNALS ARE TRANSMITTED FROM No Go to the next step.
ABS WHEEL- SPEED SENSOR USING
CURRENT DIAGNOSTIC TOOL
DLC-2.
diagnostic tool:
WSPD_LF
WSPD_LR
WSPD_RF
WSPD_RR
• Drive the vehicle.
• Verify that the wheel speed-signals are
transmitted from each ABS wheel-speed
sensor.
• Are the wheel-speed signals transmitted?
04-028-16

2 INSPECT A SHORT TO GROUND IN THE Yes Replace the rear ABS wheel-speed sensor, then go to Step
WIRING HARNESS BETWEEN THE ABS Hut 4.
CM AND THE ABS WHEEL-SPEED SENSOR (See 04-13B-7 FRONT ABS WHEEL-SPEED SENSOR
REMOVAUINSTALLATION [4W-ABS (4x2 (EXCEPT Hi-
• Turn the engine switch off. Rider))].)
• Disconnect the ABS HU/CM connector and (See 04-13B-8 FRONT ABS WHEEL-SPEED SENSOR
the ABS wheel-speed sensor connector.
• Inspect for a short to ground in the wiring (See 04-13B-10 REAR ABS WHEEL-SPEED SENSOR
harness between the following ABS wheel-
speed sensor connectors on the vehicle HEMOVAUINSTALLATION [4W-ABS (4x2 (EXCEPT Hi-
wiring harness-side and ABS HU/CM Rider»].)
connectors. (See 04-13B-11 REAR ABS WHEEL-SPEED SENSOR
- RF ABS wheel-speed sensor (+): O-A REMOVAUINSTALLATION [4W-ABS (Hi-Rider, 4x4)].)
- RF ABS wheel-speed sensor (-): M-B No Repair or replace the wiring harness, then go to the next
- LF ABS wheel-speed sensor (+): E-A step.
- LF ABS wheel-speed sensor (-): F-B
- RR ABS wheel-speed sensor (+): L-A
- RR ABS wheel-speed sensor (-): K-B
- LR ABS wheel-speed sensor (+): I-A
- LR ABS wheel-speed sensor (-): G-B
PRESENT If the malfunction recurs, replace the ABS HU/CM, then go
• Clear the DTCs from the memory. to the next step.
(See 04-13B-3 ABS HU/CM REMOVAUINSTALLATION
• Start the engine and drive the vehicle at 12 [4W-ABS].)
kmlh {7.S mph} or more. No Go to the next step.
• Are any other DTCs output?
DTC C1414 [4W-ABS]

dcf040200000w27
DTC C1414 lABS HutCM unit mismatched installation

DETECTION
• When G sensor signal input for more than 1 s to 4x2 (except Hi-Rider) vehicle-type ABS HU/CM.
CONDITION
POSSIBLE • Mismatched installation of ABS HU/CM
CAUSE - 4x2 (except Hi-Rider) vehicle type ABS HU/CM is mismatched installed on Hi-Rider and 4x4 vehicle.
1 INSPECT ABS HutCM FOR MISMATCHED Yes Go to next step.
INSTALLATION No Replace with correct ABS HU/CM part number, then go to
• Verify ABS HU/CM part number next step.
• Has a ABS HU/CM with the correct part
number been installed?
2 VERIFY CURRENT STATUS OF Yes Replace ABS HU/CM.
MALFUNCTION (See 04-13B-3 ABS HUlCM REMOVAUINSTALLATION
• Clear DTC from memory. [4W-ABS].)
(See 04-02B-2 Clearing DTCs Procedures) No Go to next step.
• Are any other DTCs output?
04-028-17
DTC C1730, C1949, C1950 [4W-ABS]
dcf04020000OW28
DTC C1730,C1949,C1950 IG sensor

• C1730
- Voltage to G sensor is detected out of range
DETECTION • C1949
- Monitor voltage of G sensor is detected at 4.7 V or more, or 0.3 V or less for more than 1 s.
CONDITION
• C1950
- G sensor O-point correction value is default or more
- Output voltage value from G sensor remains absolutely unchanged
• Open circuit in harness between ABS HU/CM terminal V and G sensor terminal C
POSSIBLE • Open, short to power, or short to ground circuit in harness between ABS HU/CM terminal P and G
sensor terminal B
CAUSE
• Open circuit in harness between ABS HU/CM terminal Wand G sensor terminal A
• Malfunction of G sensor
'c'
ABS HU/CM
~ ~
?A
"--"
G SENSOR
ABS HU/CM WIRING HARNESS-SIDE CONNECTOR G SENSOR WIRING

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1 INSPECT G SENSOR POWER SUPPLY Yes Go to the next step.
CIRCUIT FOR OPEN CIRCUIT No Repair or replace harness for open circuit between G
• Turn engine switch to ON (engine OFF). sensor terminal C and engine switch, then go to Step 7.
• Measure voltage between G sensor terminal
C (harness side) and ground.
• Is voltage B+?
2 INSPECT G SENSOR GROUND CIRCUIT FOR Yes Go to the next step.
OPEN CIRCUIT No Repair or replace harness for open circuit between ABS HU/
• Turn engine switch to OFF. CM terminal Wand G sensorterminal A, then go to Step 7.
• Disconnect ABS HU/CM and G sensor
connectors.
• Inspect continuity between ABS HU/CM
terminal W (harness side) and G sensor
terminal A (harness side).
3 INSPECT G SENSOR SIGNAL CIRCUIT FOR Yes Go to the next step.
OPEN CIRCUIT No Repair or replace harness for open circuit between ABS HU/
• Inspect continuity between ABS HU/CM CM terminal P and G sensor terminal B, then go to Step 7.
terminal P (harness side) and G sensor
terminal B (harness side).
4 INSPECT G SENSOR SIGNAL CIRCUIT FOR Yes Repair or replace harness for short to power circuit between
SHORT TO POWER ABS HU/CM terminal P and G sensor terminal B, then go to
• Turn engine switch to ON (engine OFF). Step 7.
• Measure voltage between ABS HU/CM No Go to the next step.
terminal P (harness side) and ground.
• Is voltage B+?
04-028-18

5 INSPECT G SENSOR SIGNAL CIRCUIT FOR Yes Repair or replace harness for short to ground circuit
SHORT TO GROUND between ABS HUlCM terminal P and G sensor terminal B,
• Turn engine switch to OFF. then go to Step 7.
• Inspect continuity between ABS HU/CM No Go to the next step.
terminal P (harness side) and ground.
6 INSPECT G SENSOR Yes Go to the next step.
• Inspect the G sensor. No Replace the G sensor, then go to next step.
(See 04-13B-13 G SENSOR INSPECTION (See 04-13B-12 G SENSOR REMOVAUINSTALLATION
[4W-ABS]) [4W-ABS].}
• Is it normal?
7 VERIFY DTC TROUBLESHOOTING Yes Replace the ABS HU/CM, then go to next step.
COMPLETED (See 04-13B-3 ABS HU/CM REMOVAUINSTALLATION
• Make sure to reconnect all disconnected [4W-ABS].)
• Clear the OTC from the memory.
(See 04-02B-2 Clearing OTCs Procedures.)
• Are the same OTCs present?
8 VERIFY AFTER REPAIR PROCEDURE Yes Go to the applicable OTC inspection.
• Are any other OTCs present? (See 04-02B-4 OTC Table.)
No OTC troubleshooting completed.
04-02B-1Sj
SYMPTOM TROUBLESHOOTING [4-WHEEL ANTILOCK
04-03B SYMPTOM TROUBLESHOOTING [4-WHEEL

ANTI LOCK BRAKE SYSTEM (4W-ABS)]
SYSTEM WIRING DIAGRAM NO.2 ABS WARNING LIGHT
[4W-ABS] ..•.•..........••....... 04-03B-1 DOES NOT ILLUMINATE WHEN
FOREWORD [4W-ABS] .......•.••.• 04-03B-2 THE ENGINE SWITCH IS TURNED
PRECAUTION [4W-ABS] .••••..•.•.. 04-03B-2 TO THE ON POSITION [4W-ABS] ..... 04-03B-7
SYMPTOM TROUBLESHOOTING NO.3 ABS WARNING LIGHT STAYS
[4W-ABS] ....••..•....••••..•..•. 04-03B-5 ON 4 S OR MORE WHEN THE ENGINE
NO.1 ABS WARNING LIGHT SWITCH IS TURNED TO THE ON
ILLUMINATE WHEN THE ENGINE POSITION [4W-ABS] .•..•.••..•.•.. 04-03B-7
SWITCH IS TURNED TO THE ON NO.4 THERE IS MALFUNCTION IN
POSITION [4W-ABS] ••••.....•.... 04-03B-6 THE SYSTEM EVEN THOUGH ABS
WARNING LIGHT, DO NOT
ILLUMINATE [4W-ABS] ............. 04-03B-8
SYSTEM WIRING DIAGRAM [4W-ABS]

dcf04030000Ow22
ABS/SOL20A
I
I Hi-Rider, 4x4
I
I
: Vl------I-.nI
: P G SENSOR
ABS 40A I
I
1I __ - _______________________ _
BRAKE SWITCH
~~N~~~j{~~~
BRAKE
LIGHT
ABSWARNING
LIGHT
ABS HUlCM
~~--~~---------4S Ql------n
INSTRUMENT CLUSTER
ABSWHEEL-
SPEED SENSOR
DCF413BWB001
04-038-1
FOREWORD [4W-ABS]
dcf040300000w23
• Before performing the steps in Symptom Troubleshooting, perform the On-board Diagnostic inspection. To
inspect the DTC, follow the DTC Inspection steps. (See 04-02B-4 DTC Table.)
PRECAUTION [4W-ABS]
dcf040300000w24
1. Anyone or a combination of the ABS warning illuminates even when the system is normal.
Warning lights that may Cases in which the light may Conditions in which the
ABS control
illuminate and/or flash illuminate light will go out
• ABS warning light When the front wheels are After turning ehgine switch • ABS: Cuts control.
jacked up, stuck, or placed on off, vehicle is driven at speed
a chassis roller, and only the greater than 12 km/h {7.5
front wheel ABS wheel-speed mph} and normal operation is
sensors are spun. confirmed.
Parking brake is not fully
released while driving.
Brake drag.
Sudden accelerationl
deceleration.
Left/right or front/rear tires are
different. (Size, radius, tire
pressure, or wear is other than
that listed on tire label.)
Battery voltage at ABS HU/CM Battery voltage rises above ABS: Cuts control.
ignition terminal J drops approx. 10 V.
below approx. 10 V.(1)
Battery voltage at ABS HU/CM Battery voltage drops below ABS: Cuts control.
ignition terminal J rises above approx. 16 V.
approx. 16 V.(2)
*1 : If battery voltage drops below 10 V while vehicle speed is greater than 6 km/h {3.7 mph} ,ABS Hu/CM
records DTC B1318.
*2
: If battery voltage rises above 16 V ,ABS HU/CM records DTC B1317.
2. Precautions during servicing of ABS
The ABS is composed of electrical and mechanical parts. It is necessary to categorize malfunctions as being
either electrical or hydraulic when performing troubleshooting.
(1) Malfunctions in electrical system
• The ABS hydraulic unit and control module (ABS HU/CM) has an on-board diagnostic function. With
this function, the ABS warning light and/or BRAKE system warning light will illuminate when there is a
problem in the electrical system. Also, past and present malfunctions are recorded in the ABS HU/CM.
This function can find malfunctions that do not occur during periodiC inspections. Connect the current
diagnostic tool to the DLC-2. The stored malfunctions will be displayed in the order of occurrence. To
find out the causes of ABS malfunctions, use these on-board diagnostic results.
• If a malfunction occurred in the past but is now normal, the cause is likely a temporary poor connection
of the wiring harness. The ABS HU/CM usually operates normally. Be careful when searching for the
cause of malfunction.
• After repair, it is necessary to clear the DTC from the ABS HU/CM memory. Also, if the ABS related
parts have been replaced, verify that the no DTC has been displayed after repairs.
• After repairing the ABS wheel-speed sensor or ABS sensor rotor, or after replacing the ABS CM (ABS
motor or ABS motor relay or solenoid valve), the ABS warning light may not go out even when the
engine switch is turned to the ON position. In this case, drive the vehicle at a speed of 12 km/h {7.5
mph} or more, make sure that ABS warning light goes out, and then clear the DTC.
• When repairing, if the ABS related connectors are disconnected and the engine switch is turned to the
ON position, the ABS CM will mistakenly detect a fault and record it as a malfunction.
• To protect the ABS HU/CM, make sure the engine switch is turned off before connecting or
disconnecting the ABS CM connector.
(2) Malfunctions in hydraulic system
• Symptoms in a hydraulic system malfunction are similar to those in a conventional brake malfunction.
However, it is necessary to determine if the malfunction is in an ABS component or the conventional
brake system.
• The ABS hydraulic unit contains delicate mechanical parts. If foreign material enters into the
component, the ABS may fail to operate. Also, it will likely become extremely difficult to find the location
of the malfunction in the event that the brakes operate but the ABS does not. Make sure foreign
material does not enter when servicing the ABS (e.g. brake fluid replacement, pipe removal).
04-038-2
SYMPTOM TROUBLESHOOTING [4-WHEEL ANTI LOCK
Intermittent Concern Troubleshooting
Vibration method
• If a malfunction occurs or becomes worse while driving on a rough road or when engine is vibrating, perform
the following steps.
Note
• There are several reasons why vehicle or engine vibration could cause an electrical malfunction. Inspect
the following:
Connectors not fully seated.
- Wiring harness not having full play.
- Wiring harness laying across brackets or moving parts.
- Wiring harness routed too close to hot parts.
• An improperly routed, improperly clamped, or loose wiring harness can cause pinching between parts.
• The connector joints, points of vibration, and places where wiring harness pass through the firewall, body
panels, etc. are the major areas to be inspected.
Inspection method for switch connectors or wiring harnesses

2. Turn the engine switch to the ON position (Engine OFF).
Note

4. Turn the switch on manually.
5. Slightly shake each connector or wiring harness
PID .
• If the PID value is unstable, inspect poor /
connection. /..4 /
1.;
/!J/
/ /
/ -I
/
I /1
/
I
B3E0403W005
Inspection method for sensor connectors or wiring harnesses

Note

4. Slightly shake each connector or wiring harness
PID .
• If the PID value is unstable, inspect poor
connection.
B3E0403W006
04-038-3
Inspection method for sensors
Note

4. Vibrate the sensor slightly with your finger.
• If the PID value is unstable or a malfunction occurs, inspect the sensor for poor connection and/or poor
mounting.
Malfunction data monitor method

1. Perform malfunction reappearance test according to malfunction reappearance mode and malfunction data
monitor. The malfunction cause is found in the malfunction data.
Connector terminal inspection method

1. Inspect the connection of each female terminal.
2. Insert the male terminal to the female terminal
and Inspect the female terminal for looseness.
83E0403W007
04-038-4
SYMPTOM TROUBLESHOOTING [4W-ABS]
dcf040300000w25
• Verify the symptoms, and perform troubleshooting according to the appropriate number.
No. Symptom
1 ABS warning light illuminate when the engine switch is turned to the ON position.
2 ABS warning light does not illuminate when the engine switch is turned to the ON position.
3 ABS warning light stays on 4 s or more when the engine switch is turned to the ON position.
4 There is a malfunction in the system even through ABS warning light, do not illuminate.
x: Applicable
Possible factor
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Troubleshooting item « E () .£e. E () III o 3:
1 ABS warning light illuminate when the engine X X X X
switch is turned to the ON position.
2 ABS warning light does not illuminate when X X

the engine switch is turned to the ON
position.
3 ABS warning light stays on 4 s or more when X X X X

the engine switch is turned to the ON
position.
4 There is a malfunction in the system even X X X

though ABS warning light, do not illuminate.
DBR403ZWB001
04-038-5
NO.1 ABS WARNING LIGHT ILLUMINATE WHEN THE ENGINE SWITCH IS TURNED TO THE ON POSITION
[4W-ABS]
dcf04030000Ow26
1 IABS warning light illuminate when the engine switch is turned to the ON position.
• Instrument cluster or ABS HUlCM malfunction
1 INSPECT FOR DTCs IN ABS HUlCM Yes Perform the applicable OTC inspection.
• Have OTCs been stored in memory? (See 04-02B-4 OTC Table.)
No Inspect the instrument cluster.
If the instrument cluster is normal, inspect CAN
communication.
If instrument cluster has a malfunction, go to the next step.
2 VERIFY WHETHER MALFUNCTION IS IN Yes Replace the instrument cluster. (open circuit in instrument
WARNING LIGHTS AND INDICATOR LIGHT'S cluster)
COMMON POWER SUPPLY, OR IN OTHER (See 09-22-2 INSTRUMENT CLUSTER REMOVAU
WARNING LIGHTS AND INDICATOR LIGHTS INSTALLATION.)
• Do other warning and indicator lights No Go to the next step.
illuminate when the engine switch is turned
to the ON position?
3 INSPECT INSTRUMENT CLUSTER POWER Yes Go to the next step.
SUPPLY FUSE No Inspect for a short to ground on circuit of blown fuse.
• Is the instrument cluster ignition power Repair or replace if necessary.
supply fuse normal? Install appropriate amperage fuse.
*4 VERIFY WHETHER MALFUNCTION IS IN Yes Replace the instrument cluster (open circuit in instrument
WIRING HARNESS (BETWEEN INSTRUMENT cluster).
CLUSTER POWER SUPPLY AND (See 09-22-2 INSTRUMENT CLUSTER REMOVAU
INSTRUMENT CLUSTER FOR CONTINUITY) INSTALLATION.)
OR INSTRUMENT CLUSTER No Inspect for open circuit in wiring harness between the
• Turn the engine switch to the ON position. instrument cluster and ground.
• Measure voltage at instrument cluster Repair or replace if necessary.
connector terminal 2A. Replace the ABS HU/CM.
• Is the voltage approx. 12 V? (See 04-13B-3 ABS HU/CM REMOVAUINSTALLATION
[4W-ABS].)
INSTRUMENT CLUSTER WIRING HARNESS-SIDE CONNECTOR
« :><: 'r' Inl 1101
2WI2UI2S 2QI20 2MI2K 2112G 2E 12CI2A
- -
1011MI1KI1111GI1EI1CI1A
2xI2VI2T 2RI2P 2N 12L 2J 12H 2FI2012B 1pI1NI1LI1JI1HI1FI1011B
I~, I I~, I
• When performing an asterisked () troubleshooting inspection, slightly shake the wiring harness and connectors
while performing the inspection to discover whether poor contact pOints are the cause of any intermittent
malfunction. If there is a problem, verify that the connectors, terminals and wiring harness are connected
correctly and undamaged.
04-038-6
NO.2 ABS WARNING LIGHT DOES NOT ILLUMINATE WHEN THE ENGINE SWITCH IS TURNED TO THE ON
POSITION [4W-ABS]
dcf040300000w27
2 IABS warning light does not illuminate when the engine switch is turned to the ON position.
• Open circuit between ABS HUlCM and instrument cluster
1 VERIFY WHETHER MALFUNCTION IS IN Yes Inspect for open circuit between ABS HU/CM terminal Sand
WIRING LIGHT OR CONTROL CIRCUIT instrument cluster terminal 2L.
• Turn the engine switch OFF. No Replace instrument cluster.
• Disconnect ABS HUlCM connector. (See 09-22-2 INSTRUMENT CLUSTER REMOVAU
• Short to ground at ABS HU/CM harness-side INSTALLATION.)
connector terminal S using a jumper wire.
• Turn the engine switch ON.
• Does the ABS warning light illuminate?
ASS HU/CM WIRING HARNESS-SIDE CONNECTOR
If I I I I1
I y I W I U I S 10 I 0 I M I K II I G I E II D C S A
1\ I z I X I V I T I Rip I NIL I J I H I F I ./ I""
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q ;>< "?> 1m 1m r.
2wI2UI2S 20120 2MI2K 2112G 2EI2CI2A 1011MI1KI11 1GI1EI1CL1A
2xl2Vl2T 2RI2P 2N 12L 2J 12H 2FI2DI2S 1pI1NI1LI1J 1HI1FI1Dhs
I~~I I~~I
NO.3 ABS WARNING LIGHT STAYS ON 4 S OR MORE WHEN THE ENGINE SWITCH IS TURNED TO THE ON
POSITION [4W-ABS]
dcf040300000w29
3 IABS warning light stays on 4 s or more when the engine switch is turned to the ON position.
• ABS CM detects ABS system malfunction.
• Short to ground in ABS warning light control circuit
1 INSPECT FOR DTCs IN ABS HUlCM Yes Perform the applicable DTC inspection.
• Have DTCs been stored in memory? (See 04-02B-4 DTC Table.)
No Inspect the instrument cluster
If the instrument cluster is normal, go to the next step.
If the instrument cluster has a malfunction, repair the
instrument cluster, go to the next step.
2 VERIFY WHETHER MALFUNCTION IS IN Yes Go to the next step.
( WARNING LIGHT OR CONTROL CIRCUIT No Replace the ABS HU/CM.
\, • Turn the engine switch OFF. (See 04-13B-3 ABS HU/CM REMOVAUINSTALLATION
• Disconnect the ABS HU/CM connector. [4W-ABS].)
• Turn the engine switch to ON.
• Does the ABS warning light stay on 4 s or
more?
04-038-7

3 INSPECT ABS WARNING LIGHT CONTROL Yes Repair or replace for short to ground.
CIRCUIT FOR SHORT TO GROUND No Replace instrument cluster.
• Turn the engine switch OFF. (See 09-22-2 INSTRUMENT CLUSTER REMOVAU
• ABS HU/CM connector disconnected. INSTALLATION.)
• Disconnect the instrument cluster connector.
• Verify continuity between ABS HU/CM
harness-side connector terminal S and body
ground.
ABS HUlCM WIRING HARNESS-SIDE CONNECTOR
GI I I I I
Y wi U I S 10 10 I M I K II I G I E II D C B A))
rzlxlvlTIRlplNILIJ IHIFI ~
I~~ I
« >< y::. Inl lin!
-
2wI2UI2S 20120 2MI2K 2112G 2E 12CI2A !11011M11K111 1GI1EI1CI1A
2xI2VI2T 2RI2P 2N 12L 2J 12H 2FI2DI2B '11P11N11L11J 1HI1FI1DI1B
I~~ I I~~I
NO.4 THERE IS MALFUNCTION IN THE SYSTEM EVEN THOUGH ABS WARNING LIGHT, DO NOT
ILLUMINATE [4W-ABS]
dcf04030000Ow31
4 I There is a malfunction in system even though ABS warning light, do not illuminate.
• There is a difference in size or air pressure between the front and rear tires.
1 INSPECT FOR DTCs IN ABS HUlCM Yes Perform the applicable DTC inspection.
Have DTCs been stored in memory? (See 04-02B-4 DTC Table.)
2 INSPECT ABS HYDRAULIC UNIT Yes Inspect the conventional brake system.
Perform the ABS hydraulic unit system No If the wheels do not rotate:
inspection. Replace the ABS HU/CM.
Is the system normal? (See 04-13B-3 ABS HU/CM REMOVAUINSTALLATION
[4W-ABS].)
If the wheels rotate but order in which wheels rotate is
incorrect:
Inspect the brake pipe passage to the ABS HU/CM.
i;
04-038-8
GENERAL PROCEDURES
GENERAL PROCEDURES (BRAKE) ... 04-10-1
GENERAL PROCEDURES (BRAKE)

dcf04100000Ow01
Wheel and Tire Installation
torque.
Tightening torque
88.2-117.6 N·m {9.00-11.99 Kgf.m, 65.06-86.73 ft.lbf}
Brake Lines Disconnection

1. If any brake line has been disconnected during the procedures, add brake fluid, bleed the brakes, and inspect
for leakage after the procedure has been completed.
Caution
• Brake fluid will damage painted surfaces. Be careful not to spill any on painted surfaces. If it is
spilled, wipe it off immediately.
Brake Pipe Flare Nut Tightening

1. Tighten the brake pipe flare nut using the SST (49 0259 770B).
1. Disconnect the negative battery cable before performing any work that requires handling of connectors. (See
01-17-2 BATTERY REMOVAUINSTALLATION.)
ABS Related Parts

1. Make sure that there are no DTCs in the ABS memory after working on ABS related parts. If there are any
DTCs in the memory, clear them.
04-10-1
04-11 CONVENTIONAL BRAKE SYSTEM

CONVENTIONAL BRAKE SYSTEM LOAD SENSING PROPORTIONING
LOCATION INDEX ...••..•......... 04-11-2 VALVE (LSPV)
AIR BLEEDING .•........•..•.•.••• 04-11-3 REMOVAL/INSTALLATION ....•••... 04-11-14
VACUUM LINE INSPECTION .....•.•• 04-11-3 FRONT BRAKE (DISC) INSPECTION ... 04-11-15
BRAKE PEDAL INSPECTION .••..... 04-11-4 FRONT BRAKE (DISC)
BRAKE PEDAL REMOVAL/INSTALLATION
REMOVAL/INSTALLATION .....•.••. 04-11-5 [4x2 (EXCEPT Hi-Rider)] .•.........• 04-11-16
BRAKE SWITCH FRONT BRAKE (DISC)
REMOVAL/INSTALLATION ....•..•.. 04-11-5 REMOVAL/INSTALLATION
BRAKE SWITCH INSPECTION ....... 04-11-6 [Hi-Rider,4x4] ••....••.•.•..•..... 04-11-17
MASTER CYLINDER DISC PAD (FRONT) REPLACEMENT
REMOVAL/INSTALLATION .•••.•..•. 04-11-6 [4x2 (EXCEPT Hi-Rider)] •.•......... 04-11-19
BRAKE FLUID LEVEL SENSOR DISC PAD (FRONT) REPLACEMENT
INSPECTION •...•.........••.••.• 04-11-7 [H i-Rider, 4x4] ••....•..••.•....... 04-11-20
MASTER CYLINDER CALIPER (FRONT)
DISASSEMBLY/ASSEMBLY •••...... 04-11-8 DISASSEMBLY/ASSEMBLY
POWER BRAKE UNIT INSPECTION ... 04-11-9 [4x2 (EXCEPT Hi-Rider)] .....•...... 04-11-20
POWER BRAKE UNIT CALIPER (FRONT)
REMOVAL/INSTALLATION .••..•.••. 04-11-10 DISASSEMBLY/ASSEMBLY
VACUUM PUMP INSPECTION ..•.•... 04-11-11 [Hi-Rider, 4x4] ..••••.•...•..•.•... 04-11-21
VACUUM PUMP REAR BRAKE (DRUM) INSPECTION .•. 04-11-22
REMOVAL/INSTALLATION •......... 04-11-11 REAR BRAKE (DRUM)
LOAD SENSING PROPORTIONING REMOVAL/INSTALLATION ..••...... 04-11-23
VALVE (LSPV) INSPECTION ........ 04-11-12 WHEEL CYLINDER
LOAD SENSING PROPORTIONING DISASSEMBLY/ASSEMBLY •........ 04-11-25
VALVE (LSPV) ADJUSTMENT ...•••. 04-11-13
04-11-1
CONVENTIONAL BRAKE SYSTEM LOCATION INDEX
dcf04110000Ow01
DCF411 ZWB001
1 Brake fluid 9 Front brake (disc)

(See 04-11-3 AIR BLEEDING.) (See 04-11-15 FRONT BRAKE (DISC)
2 Vacuum line INSPECTION.)
(See 04-11-3 VACUUM LINE INSPECTION.) (See 04-11-16 FRONT BRAKE (QISC) REMOVAU
INSTALLATION [4x2 (EXCEPT Hi-Rider)].)
3 Brake pedal
(See 04-11-17 FRONT BRAKE (DISC) REMOVAU
(See 04-11-4 BRAKE PEDAL INSPECTION.)
INSTALLATION [Hi-Rider, 4x4].)
(See 04-11-5 BRAKE PEDAL REMOVAU
(See 04-11-19 DISC PAD (FRONT)
INSTALLATION.)
REPLACEMENT [4x2 (EXCEPT Hi-Rider)].)
4 Brake switch (See 04-11-20 DISC PAD (FRONT)
(See 04-11-5 BRAKE SWITCH REMOVAU REPLACEMENT [Hi-Rider, 4x4].)
INSTALLATION.) (See 04-11-20 CALIPER (FRONT) DISASSEMBLY/
(See 04-11-6 BRAKE SWITCH INSPECTION.) ASSEMBLY [4x2 (EXCEPT Hi-Rider)].)
5 Master cylinder (See 04-11-21 CALIPER (FRONT) DISASSEMBLY/
(See 04-11-6 MASTER CYLINDER REMOVAU ASSEMBLY [Hi-Rider, 4x4].)
INSTALLATION.) 10 Rear brake (drum)
(See 04-11-7 BRAKE FLUID LEVEL SENSOR (See 04-11-22 REAR BRAKE (DRUM)
(See 04-11-8 MASTER CYLINDER DISASSEMBLY/ (See 04-11-23 REAR BRAKE (DRUM) REMOVAU
ASSEMBLY.) INSTALLATION.)
6 Power brake unit (See 04-11-25 WHEEL CYLINDER DISASSEMBLY/
(See 04-11-9 POWER BRAKE UNIT INSPECTION.) ASSEMBLY.)
(See 04-11-10 POWER BRAKE UNIT REMOVAU
INSTALLATION.)
7 Vacuum pump
(See 04-11-11 VACUUM PUMP INSPECTION.)
(See 04-11-11 VACUUM PUMP REMOVAU
INSTALLATION.)
8 Load sensing proportioning valve (LSPV)
(See 04-11-12 LOAD SENSING PROPORTIONING
VALVE (LSPV) INSPECTION.)
VALVE (LSPV) ADJUSTMENT.)
VALVE (LSPV) REMOVAUINSTALLATION.)
04-11-2
AIR BLEEDING
dcf04110000Ow02
Caution
• Brake fluid will damage painted surfaces. Be careful not to spill any on painted surfaces. If it is
Note
• Keep the fluid level in the reserve tank at 3/4 full or more during the air bleeding.
• Begin air bleeding with the brake caliper that is furthest from the master cylinder.
Brake fluid type

SAE J1703, FMVSS 116 DOT-3
1. Remove the bleeder cap on the brake caliper, and attach a vinyl tube to the bleeder screw.
2. Place the other end of the vinyl tube in a clear container and fill the container with fluid during air bleeding.
3. Working with two people, one should pump the brake pedal several times and depress and hold the pedal
down.
4. While the brake pedal is depressed, the other
should loosen the bleeder screw using the SST,
drain out any fluid containing air bubbles, and
tighten the bleeder screw.
Tightening torque
Front (4x2 (except Hi-Rider»: 9-14 N·m
{92-142 kgf·cm, 80-123 in.lbf}
Front (Hi-Rider, 4x4): 5.9-8.8 N·m {61-89
kgf·cm, 53-77 in.lbf}
Rear: 5.9-8.8 N·m {61-89 kgf.cm, 53-77
in.lbf}
DBR411ZWB002 ~
5. Repeat Steps 3 and 4 until no air bubbles are

seen. IWII
6. Perform air bleeding as described in the above procedures for all brake calipers.
7. After air bleeding, inspect the following:
• Brake operation
• Fluid leakage
• Fluid level
VACUUM LINE INSPECTION

dcf04114364Ow01
1. Remove the vacuum hose.

2. Verify that air can be blown from the power brake
WL-3
unit side of the vacuum hose towards the vacuum
pump side, and that air cannot be blown in the
opposite direction.
• If there is any malfunction of the inner check
valve, replace it together with the vacuum
hose as a single unit.
•
WL-C, WE-C
TO VACUUM PUMP
t DBR411ZWB003
04-11-3
BRAKE PEDAL INSPECTION
dcf04114330Ow01
Brake pedal Height Inspection

1. Measure the distance from the center of the
upper surface of the pedal pad to the floor panel
and verify that it is as specified.
brake pedal. PEDAL HEIGHT
Brake pedal height

214-219 mm {8.43-8.62 in}
DBR411ZWB004
Brake Pedal Height Adjustment

1. Disconnect the brake switch connector.
2. Loosen locknut B and turn switch A until it does not contact the pedal.
3. Loosen locknut D and turn rod C to adjust the height.
4. Tighten the turn rod C with locknut D.
Tightening torque
24-34 N·m {2.5-3.4 kgf·m, 18-25 ft.lbf}
5. Tighten the bolt with locknut B so that clearance

between the bolt for brake switch A and pedal
stopper is within the specification.
Specification
0.1-1.0 mm {0.004-0.039}
Tightening torque
13.7-17.6 N·m {140-179 kgf·cm, 122-155
in.lbf}
6. Connect the brake switch connector.

7. After adjustment, inspect the pedal play and the
DBR411 ZWB005
brake light operation.
Brake Pedal Play Inspection

1. Pump the pedal several times to release the vacuum in the power brake unit.
2. Remove the snap pin, verify that the holes in the fork and in the pedal are aligned, and reinstall the pin.
3. Gently depress the pedal by hand until resistance
is felt (approx. 20 N {2.0 kgf, 4.5 Ibf}) and
measure the pedal play.
Standard pedal play

3.0-8.0 mm {0.12-0.31 in}
DBR411ZWB006
04-11-4
Brake Pedal Play Adjustment
1. Remove the snap pin and clevis pin.
2. Loosen locknut D and turn rod C to align the holes in the fork and in the pedal.
3. Install the clevis pin ant the snap pin.
4. Tighten locknut D.
Tightening torque
24-34 N·m {2.5-3.4 kgf.m, 18-25 ft.lbf}
5. After adjustment, inspect the pedal height and the

brake light operation.
DBR411 ZWB007
Pedal-to-floor Clearance Inspection

1. Start the engine and depress the brake pedal with a force of 589 N {GO kgf, 132 Ibf}.
2. Measure the distance from the center of the
upper surface of the pedal pad to the floor
covering and verify that it is as specified .
• If it is less than the specification, inspect the
following:
Air in brake system
- Malfunction of the automatic adjuster
- Excessive shoe clearance
II
Standard pedal-to-floor clearance
105 mm {4.14 in} or more
L---------------~------------~DB~R~41~1Z~W~BO~08
BRAKE PEDAL REMOVAL/INSTALLATION

dcf041143300w02
1. The brake pedal is mounted on the bracket integrated with the clutch pedal and accelerator pedal. Refer to
section 01, INTAKE AIR SYSTEM, ACCELERATOR PEDAL REMOVAL/INSTALLATION for the brake pedal
removal/installation. (See 01-13A-9 ACCELERATOR PEDAL COMPONENT REMOVAUINSTALLATION [WL-
3].) (See 01-13B-11 ACCELERATOR PEDAL COMPONENT REMOVAUINSTALLATION [WL-C, WE-C).)
BRAKE SWITCH REMOVAL/INSTALLATION

dcf041166490w01
2 Brake switch
3 Nut

3. After installation, inspect the brake pedal. (See
04-11-4 BRAKE PEDAL INSPECTION.)
N·m {kgf·cm, in.lbf}

DBR411 ZWB053
04-11-5
BRAKE SWITCH INSPECTION
dcf041166490w02
1. Remove the lower panel.
2. Disconnect the brake switch connector.
table.
brake switch. (See 04-11-5 BRAKE SWITCH
0--0 : Continuity
Terminal
Condition
A B
When the brake pedal
is depressed DBR41 1ZWB009
When the brake pedal

is not depressed
DBR41 1ZWB052
MASTER CYLINDER REMOVAUINSTALLATION

dcf041143400w01
2
mI" WITHOUT 4W·ABS
12.8-21.6
{131-220,114-191}
N.m {kgf.cm, in.lbf}
arnffw00001966
1 Brake fluid level sensor connector 4 IMaster cylinder

2 Brake pipe 5 O-ring (AT)
3 Bracket
04-11-6
BRAKE FLUID LEVEL SENSOR INSPECTION
dcf041143400w02
1. Disconnect the brake fluid level sensor connector from the master cylinder.
2. Inspect for continuity according to fluid level ...--------------------,
between the brake fluid level sensor terminals.
brake fluid level sensor. (See 04-11-6
MASTER CYLINDER REMOVAU
INSTALLATION.)
0--0: Continuity
Terminal
Condition
A B
DBR411ZWB017
Above MIN
Below MIN
CHU0411W017
04-11-7
MASTER CYLINDER DISASSEMBLY/ASSEMBLY
dcf04114340OW03
1. After removing the brake fluid, disassemble in the order indicated in the table.
WITHOUT 4W-ABS
WITH4W-ABS
.~~
A 1
~~e
~~ "®1lI
~1iI
~.~ I iii
o ~
18
~~ 1.47-2.94
{15.0-29.9,13.1-26.0}
DCF411ZWB003
1 Cap set 12 Primary piston stopper

2 Pin 13 Primary piston
3 Reservoir 14 Stop screw (without 4W-ABS)
4 Joint bushing (See 04-11-9 Stop Screw (without 4W-ABS)
Assembly Note)
5 Brake fluid level sensor
15 Stop screw (with 4W-ABS)
6 Seal and plate assembly (See 04-11-9 Stop Screw (with 4W-ABS) Assembly
7 Snap ring Note.)
8 Spacer 16 Gasket
9 Piston guide 17 Secondary piston
10 O-ring 18 Master cylinder body
11 Cup
04-11-8
Stop Screw (with 4W-ABS) Assembly Note
1. Install the secondary piston component with the piston hole facing the stop pin.
2. Install and tighten a new gasket and the stop pin.
3. Push and release the piston to verify that it is held
by the stop pin.
A6E6912W043
Stop Screw (without 4W-ABS) Assembly Note

1. Push the primary piston component in fully.
2. Install and tighten a new gasket and the stop
screw.
3. Push and release the piston to verify that it is held
by the stop screw.
A6E6912W025 ~
POWER BRAKE UNIT INSPECTION
dcf041143800wOl ~
Power Brake Unit Function Inspection (Inspection using gauges)
1. Connect the SST gauges, a vacuum gauge, and a r-=----.:=--ii]Dimmm---------1
pedal depression gauge as shown in the figure. I
Bleed the air from the SST gauges before
performing the following tests.
DBR411 ZWB019
Checking for vacuum loss (unloaded condition)

1. Start the engine.
2. Stop the engine when the vacuum gauge indicates 67 kPa {500 mmHg, 20 inHg}.
3. Observe the vacuum gauge for 15 s .
• If the gauge indicates 64-66 kPa {476-499 mmHg, 18.8-19.6 inHg}, the unit is operating.
Checking for vacuum loss (loaded condition)

2. Depress the brake pedal with a force of 200 N {20 kgf, 45 Ibf}.
3. With the brake pedal held depressed, stop the engine when the vacuum gauge indicates 67 kPa {500 mmHg,
20 inHg}.
4. Observe the vacuum gauge for 15 s .
• If the gauge indicates 64-66 kPa {476-499 mmHg, 18.8-19.6 inHg}, the unit is operating.
04-11-9
Checking for hydraulic pressure
1. If the engine is stopped (vacuum 0 kPa {O mmHg, 0 inHg}) and the fluid pressure is within the specification,
the unit is operating.
Power brake unit fluid pressure when pedal depressed at 200 N {20 kgf, 45 Ibf}
At 0 kPa {O mmHg, 0 inHg}: 593 kPa {6.1 kgf/cm 2 , 87 psi} or more
2. Start the engine. Depress the brake pedal when the vacuum reaches 67 kPa {500 mmHg, 20 inHg}.
• If the fluid pressure is within the specification, the unit is operating.
• If the fluid pressure is not as specified, inspect for damage to the check valve or vacuum hose, and fluid
leakage of the hydraulic line. Repair as necessary, and inspect again.
Power brake unit fluid pressure when pedal depressed at 200 N {20 kgf, 45 Ibf}
At 67 kPa {500 mmHg, 20 inHg}: 6,950 kPa {71 kgflcm 2 , 1,008 psi} or more
POWER BRAKE UNIT REMOVAUINSTALLATION

dcf04114380Ow02
1. Remove the master cylinder. (See 04-11-6 MASTER CYLINDER REMOVAUINSTALLATION.)
2. For vehicles with 4W-ABS, disconnect all the ABS
HU/CM brake pipes shown inthe figure. (See 04-
16-22
13B-3 ABS HU/CM REMOVAUINSTALLATION {1.7-2.2,
[4W-ABS].) 12-16}
3. Remove the brake pipe (ABS HU/CM-master
cylinder).

DBR411 ZWB049

1 Vacuum hose
2 Snap pin
3 Clevis pin
4 Nut
5 Power brake unit
6 Gasket
7 Fork 3
8 Nut
23.54-34.32
{2.401-3.499,17.37-25.31}
5
DBR411 ZWB020
04-11-10
,
VACUUM PUMP INSPECTION
dcf041118777w01
1. Warn up the engine.

2. Disconnect the vacuum hose from the vacuum
pump and connect a vacuum gauge as shown in
the figure, then check the vacuum.
• If the pressure is less than the specification,
inspect for the following.
- Malfunction of the vacuum pump
- Shortage of the lubrication oil pressure
Vacuum specification (In 20 s)

Engine speed 1,270 rpm: 74 kPa {550 mmHg,
22 inHg} or more
Engine speed 2,450 rpm: 94 kPa {700 mmHg,
DBR411 ZWB023
28 inHg} or more
VACUUM PUMP REMOVAUINSTALLATION

dcf041118777w02
1. Remove the battery and battery tray. (See 01-17-2 BATTERY REMOVAUINSTALLATION.)
2. Remove the clip shown in the figure.
CLIP
'-----_ _~II DBR614ZWB020

1 Bracket (WL-C, WE-C)
2 Vacuum hose
3 Bolt
4 Vacuum pump
5 O-ring
18.6-25.5 18.6-25.5
{1.9-2.6, {1.9-2.6,13.8-18.8}
13.8-18.8}
DBR411ZWB022
04-11-11
LOAD SENSING PROPORTIONING VALVE (LSPV) INSPECTION
dcf041143903w01

2. Check the tire inflations and set them to the recommended pressure if necessary.
• If not as specified, replace or adjust.
3. Check the vehicle with a person in the driver's seat; include the standard vehicle tools, the spare wheel and tire,
and a full tank of fuel.
4. Install the SST to the front wheel cylinder and rear
wheel cylinder, then bleed the air in the brake line
and LSPV using a air bleed valve A.
DBR411 ZWB025
5. Inspect the fluid pressure of rear wheel cylinder

while the fluid pressure of front wheel cylinder is
4,900 kPa {50 kgf/cm 2 , 711 psi} and 9,800 kPa REAR LOADED
PRESSURE
{100 kgf/cm 2 , 1,421 psi}. ----------- ---------~-.
• If not as specified, adjust the LSPV. • __ • : A PERSON IN
-- : DRIVER'S SEAT
,,,
,,
,
4,900 {50, 711} 9,800 {1 00, 1,421}
FRONT PRESSURE-
kPa {kgf/cm~ psi}
DBR411ZWB026 \
Load sensing proportioning valve (LSPV) fluid pressure

Front wheel cylinder fluid pressure Rear wheel cylinder
Type
(kPa {kgf/cm 2 , psi}) (kPa {kgf/cm 2 , psi})
4,900 {50, 711} 2,250-2,850 {23-29, 327-413}
Without 4W-ABS
4x2 (except Hi- 9,800 {1 00, 1,421} 3,130-3,930 {32-40, 454-569}
Rider) 4,900 {50, 711} 2,910-3,710 {3D-37, 423-538}
With4W-ABS
9,800 {1 00, 1,421} 4,970-6,170 {51-62, 721-894}
4,900 {50, 711} 2,250-2,850 {23-29, 327-413}
Without 4W-ABS
9,800 {1 00, 1,421} 3,130-3,930 {32-40, 454-569}
Hi-Rider, 4x4
4,900 {50, 711} 2,650-3,450 {28-35, 385-500}
With4W-ABS
9,800 {1 00, 1,421} 4,700-5,900 {48-60, 682-855}
Note
• When applying the specified pressure, the brake pedal must not be "double pumped" or released.
• Read the rear pressure. After approx. 2 s elapse from setting the front wheel cylinder fluid pressure.
04-11-12
LOAD SENSING PROPORTIONING VALVE (LSPV) ADJUSTMENT
dcf041143903w02
1. Place the unloaded vehicle on level ground. Unloaded: Fuel tank is full. Engine coolant and tire, jack and tools
are in designated position.
Note
• A change of 5 mm {O.20 in} in dimension L results in a change of the following.
Type Change (kPa {kgf/cm 2 , psi})

without 4W-ABS 850 {8.7, 123}
4x2 (except Hi-Rider)
with 4W-ABS 1,020 {10, 148}
without 4W-ABS 1,060{11,154}
Hi-Rider, 4x4
with 4W-ABS 1,080 {11, 157}
2. Adjust main spring dimension L between the LSPV and the adjustment link loosening and repositioning the
LSPV.
4x2 (EXCEPT Hi· Rider) Hi-Rider, 4x4
MAIN SPRING
'X
MAIN SPRING
''''"
' '.
./ ADJUSTMENT LINK
<
DCF411 ZWB004
• Decrease dimension L if the fluid pressure is low.

• Increase dimension L if the fluid pressure is high.
Specification
Dimension L
Type Dimension L (mm {in})

without 4W-ABS
4x2 (except Hi-Rider) 147.5-154.5 {5.808-6.082}
with 4W-ABS
without 4W-ABS
Hi-Rider, 4x4 175.5-182.5 {6.910-7.185}
with 4W-ABS
3. Tightening the nut.
Specification
18.6-25.4 N·m {1.90-2.59 kgf.m, 13.8-18.7 ft.lbf}
4. After adjustment, recheck the fluid pressure.

• If not as specified, replace the LSPV as a component.
04-11-13
LOAD SENSING PROPORTIONING VALVE (LSPV) REMOVAUINSTALLATION
dcf041143903w03
Caution
• Do not disassemble the load sensing proportioning valve (LSPV) or move nut A, otherwise the
LSPV may not function properly.

3. After installation, adjust the main spring dimension. (See 04-11-13 LOAD SENSING PROPORTIONING VALVE
(LSPV) ADJUSTMENT.)
mJ' 4x2 (EXCEPT Hi-Rider)

WITHOUT 4W-ABS
12.8-21.6 N·m
{131-220 kgf·cm,
114-191 in.lbf}
Hi-Rider, 4x4
18.6-25.4
{1.9D-2.59, 13.8-18.7}
],.13.
18.6-25.4
_18,7)
mJ' 49 0259 770B N·m {kgf·m, tt·lbf}

DCF411 ZWB005
1 Brake pipe Bolt

(See 04-11-14 Brake Pipe Installation Note) Load sensing proportioning valve (LSPV)
2 Nut
Brake Pipe Installation Note

1. Install the brake pipe to the LSPV and align yellow
painting on the brake pipe and LSPV.
YELLOW PAINTING
DBR411 ZWB029
04-11-14
FRONT BRAKE (DISC) INSPECTION
dcf04113398Ow01
Disc Pad Thickness Inspection
1. Jack up the front of the vehicle on level ground and support it with safety stands.
2. Remove the wheels.
3. Look through the caliper inspection hole and
verify the remaining thickness of the pad.
Minimum front disc pad thickness

2.0 mm {0.079 in} min.
DBR411 ZWB036
Disc Plate Thickness Inspection

1. Measure the thickness of the disc plate.
• If the thickness is not within the specification,
replace the disc plate.
Caution
• When it is necessary to machine the disc
plate, make sure the disc plate is not
removed from the vehicle when
machined, excessive runout may result.
Machine the disc plate with it installed on
the vehicle.
Standard front disc plate thickness

L-------------------------------A~B~R6=9~12~WO~10~
4x2 (except Hi-Rider): 24.0 mm {0.945 in}
Hi-Rider, 4x4: 28.0 mm {1.11 in}
Minimum front disc plate thickness

Hi-Rider, 4x4: 26.0 mm {1.03 in}
Minimum front disc plate thickness after machining using a brake lathe on-vehicle
Hi-Rider, 4x4: 26.8 mm {1.06 in}
Disc Plate Runout Inspection

1. Tighten the disc plate to the wheel hub using two
wheel nuts. When measuring runout, measure at
the outer edge of the disc plate surface.
Front disc plate runout limit

0.05 mm {0.002 in} max.
04-11-15
FRONT BRAKE (DISC) REMOVAUINSTALLATION [4x2 (EXCEPT Hi-Rider)]
dcf04113398Ow02
Note
• Because the disc plate is installed to the front wheel hub, refer to WHEEL HUB, STEERING KNUCKLE
REMOVAL/INSTALLATION to remove it. (See 03-11-4 WHEEL HUB, STEERING KNUCKLE REMOVAL/
INSTALLATION [4x2 (EXCEPT Hi-Rider)].)

3. After installation, depress the pedal a few times, rotate the wheel by hand, and verify that the brake does not
drag.
108-127
,",'" H '-'. ".7--03.6,
4
I
-~
iii
-!P.
II
C!
RUBBER GREASE
DBR411 ZWB030
1 Brake hose 6 Disc pad

2 Bolt (See 04-11-16 Disc Pad Installation Note)
3 Guide pin 7 Plate
4 Dust boot 8 Guide plate
5 Caliper 9 Mounting support
Disc Pad Installation Note

1. Push the piston fully inward using the SST.
2. Install the disc pad.
04-11-16
FRONT BRAKE (DISC) REMOVAUINSTALLATION [Hi-Rider, 4x4]
dcf041133980w03
Caution

3. After installation, depress the pedal a few times, rotate the wheel by hand, and verify that the brake does not
drag.
6@
II RUBBER GREASE
6@
II BRAKE GREASE
10
DBR411ZWB035
1 Brake hose 7 Inner shim (cover shim)

2 Caliper (See 04-11-18 Outer Shim, Inner shim Installation
Note)
3 Guide pin
8 Inner shim (rubber coated shim)
Disc pad
4 (See 04-11-18 Outer Shim, Inner shim Installation
(See 04-11-19 Disc Pad Installation Note)
Note)
5 Outer shim (cover shim)
9 Guide plate
(See 04-11-18 Outer Shim, Inner shim Installation
(See 04-11-18 Guide Plate Removal Note)
Note)
10 Mounting support
6 Outer shim (rubber coated shim)
(See 04-11-18 Outer Shim, Inner shim Installation 11 Dust boot
Note) 12 Disc plate
(See 04-11-18 Disc Plate Removal Note)
(See 04-11-18 Disc Plate Installation Note)
04-11-17
Guide Plate Removal Note
1. Pull up and at a slant on the supporting part of the
guide plate in the direction indicated by the arrow
(1) and (2) as shown in the figure, to remove the
guide plate from the mounting support.
Caution
• If the guide plate is removed by pulling in
the direction indicated by the arrow as GUIOE PLATE
shown in the figure, the stopper may be
deformed and not able to be reused. Do
not remove in this manner.
DBR411 ZWB054
Disc Plate Removal Note

1. Mark the wheel hub bolt and disc plate before
removal for reference during installation.
DBR411 ZWB021
Disc Plate Installation Note

1. Remove any rust or grime on the contact face of the disc plate and wheel hub.
2. Install the disc plate and align the marks made before removal.
Outer Shim, Inner shim Installation Note

1. Assemble the rubber coated shim to the back plate of the disc pad.
2. Apply brake grease to the rubber coated shim as r-----------R-U-BB-E-R-C-O-A-T-E-O-S-H-IM----.
APPLICATION LOCATION
OF GREASE (3 PLACES)
DBR411 ZWB038
04-11-18
3. Assemble the cover-shim to the grease-applied
rubber coated shim.
Caution
• Be careful not to get any grease on the
pad lining surface.
DBR411 ZWB048
Disc Pad Installation Note

1. Push the piston fully inward using the SST.
2. Install the disc pad.
DBR411 ZWB055
DISC PAD (FRONT) REPLACEMENT [4x2 (EXCEPT Hi-Rider)]

dcf041133630w01

1 Bolt
2
3
Caliper
Guide pin
1m
28-34N·m
4 Disc pad {2.9-3.4 kgf·m.
21-25 ft.lbf}
(See 04-11-16 Disc Pad Installation Note.)
5 Plate
6 Guide plate
4
mD
DBR411ZWB032
04-11-19
DISC PAD (FRONT) REPLACEMENT [Hi-Rider, 4x4]
dcf04113363Ow02
1. Remove in the order indicated in the table. 29-34
1 Bolt CD {3.0-3.4, 22-25}
2 Caliper
3 Guide pin
4 Disc pad
(See 04-11-19 Disc Pad Installation Note) 3
5 Outer shim (cover shim)
6 Outer shim (rubber coated shim)
7 Inner shim (cover shim)
8 Inner shim (rubber coated shim)
9 Guide plate
(See 04-11-18 Guide Plate Removal Note)
-:-.!..@
I RUBBER GREASE
-:-.!..@
I BRAKE GREASE
DBR411 ZWB037
CALIPER (FRONT) DISASSEMBLY/ASSEMBLY [4x2 (EXCEPT Hi-Rider)]

dcf04113399Ow01
1 Piston
(See 04-11-21 Piston Disassembly Note)
2 Dust seal
3 Piston seal
4 Bleeder cap
5 Bleeder screw
6 Caliper
-!i
!&I
I RUBBER GREASE
mi' 49 0259 7708
DBR411 ZWB033
04-11-20
Piston Disassembly Note
Caution
• The piston could be damaged if blown out with great force. Blow the compressed air slowly to
prevent the piston from suddenly popping out.
1. Place the piece of wood in the caliper, then blow

compressed air through the hole to force the
piston out of the caliper.
DBR411ZWB034
CALIPER (FRONT) DISASSEMBLY/ASSEMBLY [Hi-Rider, 4x4]

dcf041133990w02

1 Dust seal mJ * 5.9-B.B N·m {51-B9 kgf·cm, 53-77 in·lbf}
2 Piston
(See 04-11-21 Piston Disassembly Note)
3 Piston seal
4 Bleeder cap
5 Bleeder screw
6 Caliper
DBR411 ZWB039
Piston Disassembly Note
Caution
• The piston could be damaged if blown out with great force. Blow the compressed air slowly to
prevent the piston from suddenly popping out.
1. Place the SST in the caliper, then blow

compressed air through the hole to force the
piston out of the caliper.
04-11-21
REAR BRAKE (DRUM) INSPECTION
dcf04112625Ow01
Brake Lining Thickness Inspection

1. Remove the brake drum. (See 04-11-23 REAR BRAKE (DRUM) REMOVAL/INSTALLATION.)
2. Inspect the brake lining thickness.
• If it less than the minimum specification,
replace the brake shoe. (See 04-11-23 REAR
BRAKE (DRUM) REMOVAL/INSTALLATION.)
Minimum rear brake lining thickness

1.0 mm {0.04 in}
DBR411 ZWB042
Brake Drum Inspection

1. Remove the brake drum. (See 04-11-23 REAR BRAKE (DRUM) REMOVAL/INSTALLATION.)
2. Inspect the inner diameter of the brake drum.
• If t exceeds the maximum specification,
replace the brake drum. (See 04-11-23 REAR
BRAKE (DRUM) REMOVAL/INSTALLATION.)
Maximum rear brake drum diameter

Hi-Rider, 4x4: 296.5 mm {11.67 in}
I·
DBR411ZWB041
3. Apply chalk to the inside of the brake drum, rub it

against the brake shoe, and then inspect for
scratches and uneven or abnormal wear inside
the drum.
• If there is significant uneven wear of the brake
drum, repair it within the maximum brake
drum inner diameter or replace. (See 04-11-
23 REAR BRAKE (DRUM) REMOVAL/
INSTALLATION.)
4. After inspection, wipe the chalk off.
DBR411 ZWB050
04-11-22
REAR BRAKE (DRUM) REMOVAL/INSTALLATION
dcf041126250w02
Warning
• When removing/installing the brake drum component parts, the spring could fly off and cause
injury. Remove/install the spring being careful not to allow the spring to fly off. Wear protective
equipment such as safety glasses if necessary.

3. After installation, pump the brake pedal a few times and inspect the following:
Parking brake lever stroke
Brake drag
11
APPLY I
-Y.
TO SHADED AREA
mI' 49 0259 770B

DBR411ZWB040
1 Brake drum 9 Lower return spring

(See 04-11-24 Brake Drum I nstallation Note.) 10 Hold spring (trailing shoe side)
2 Pawl spring 11 Hold pin (trailing shoe side)
3 Pawl lever 12 Parking brake cable
4 Upper return spring 13 Brake shoe (trailing shoe)
(See 04-11-24 Upper Return Spring Removal Note.)
14 U-ring
(See 04-11-24 Upper Return Spring Installation
Note.) 15 Operating lever
5 Hold spring (leading shoe side) 16 Brake pipe
6 Hold pin (leading shoe side) 17 Wheel cylinder
7 Adjust strut 18 Gasket
8 Brake shoe (leading shoe)
04-11-23
KE SYSTEM
CONVENTIONALBR=A==______
al Note
~~~~~~f
Upper Return e ~eturn Spring.usl~gWith
S ring Remov . a flathead
the hand, as
1. screwdriver
Remove. th w.hile supporting It .t
to prevent I r f om flying off.
shown ·In the figure,
II tion Note
S ring Insta ~
Upper Return et~rnspring u~lng.awith
flathead
the hand, as
1. Installt~e r hile supporting It .t f om flying off.
screwdriver w. to prevent I r
shown ·In the figure,
lIation Note f the rear brake

Brake Drum Inslah component part 0 wn in the figure.
1. Verify t~at eacerly installed as s 0
(drum) IS prop h
DBR411 ZWB056
04-11-24
2. Turn the adjuster on the adjustment strut to adjust
the brake shoe until the outer diameter (M) of the
brake shoe is as specified below.
Brake shoe adjustment value

• 4x2 (except Hi-Rider): 269.3-269.7 mm
{10.603-10.618 in}
• Hi-Rider, 4x4: 294.3-294.7 mm {11.59-
10.60 in}
3. Install the brake drum.

4. Depress the brake pedal five times and operate
DBR411 ZWB051
the auto adjuster.
5. Verify there is no brake drag.
• If there is any brake drag, readjust the brake adjustment
WHEEL CYLINDER DISASSEMBLY/ASSEMBLY

dcf041126610w01
Caution
• Replace the wheel cylinder component if a problem is found.

1 Dust boot
2 Wheel cylinder piston
3 Piston cup
4 Wheel cylinder spring
5 Bleeder cap
6 Bleeder screw
7 Wheel cylinder body
I§§J* 49 0259 770B

DBR411 ZWB045
04-11-25
04-12 PARKING BRAKE SYSTEM

PARKING BRAKE SYSTEM LOCATION PARKING BRAKE CABLE REMOVAU
INDEX .••..•.•.............•.... 04-12-2 INSTALLATION [WL-3] ...••..•..•.. 04-12-5
PARKING BRAKE LEVER PARKING BRAKE CABLE REMOVAU
INSPECTION .....•....•••....••.. 04-12-3 INSTALLATION
PARKING BRAKE LEVER [WL-C (EXCEPT Hi-Rider)] ••..••.•.. 04-12-6
ADJUSTMENT •..••........••...• 04-12-3 PARKING BRAKE CABLE REMOVAU
PARKING BRAKE LEVER REMOVAU INSTALLATION
INSTALLATION .......••••••...... 04-12-4 [WL-C (Hi-Rider), WE-C] ............ 04-12-7
PARKING BRAKE SWITCH
INSPECTION •..•..••.••••..••.•.. 04-12-8
04-12-1
PARKING BRAKE SYSTEM LOCATION INDEX
dcf041200000w01
WL-3
WL-C (EXCEPT Hi-Rider)
WL-C (Hi-Rider), WE-C
DCF412ZWB001
Parking brake lever 2 Parking brake cable

(See 04-12-3 PARKING BRAKE LEVER (See 04-12-5 PARKING BRAKE CABLE
. INSPECTION.) REMOVAUINSTALLATION [WL-3].)
(See 04-12-3 PARKING BRAKE LEVER (See 04-12-6 PARKING BRAKE CABLE
ADJUSTMENT.) REMOVAUINSTALLATION [WL-C (EXCEPT Hi-
(See 04-12-4 PARKING BRAKE LEVER Rider)].)
REMOVAUINSTALLATION.) (See 04-12-7 PARKING BRAKE CABLE
REMOVAUINSTALLATION [WL-C (Hi-Rider), WE-
C].)
3 Parking brake switch
(See 04-12-8 PARKING BRAKE SWITCH
INSPECTION.)
04-12-2
PARKING BRAKE LEVER INSPECTION
dcf04124430Ow01
Parking Brake Lever Stroke Inspection
1. Pump the brake pedal a few times.
2. Pull the parking brake lever two to three times.
3. Verify that the stroke is within the specification when the parking brake lever is pulled with a force of 98 N {10
kgf, 22 Ibf} .
• If not within the specification, adjust the parking brake lever. (See 04-12-3 PARKING BRAKE LEVER
ADJUSTMENT.)
Parking brake lever stroke when pulled at 98 N {10 kgf, 22 Ibf}

1-7 notches
PARKING BRAKE LEVER ADJUSTMENT

dcf041244300w02
Parking Brake Lever Stroke Adjustment
1. Before adjustment, depress the brake pedal several times while the vehicle is moving in reverse.
2. Loosen the locknut A and turn the adjustment nut B so that the stroke is within the above range.
3. After adjustment, tighten the locknut A. _________~ ~
Tightening torque ~ ~ /
6.9-9.8 N·m {71-99 kgf·cm, 62-86 in.lbf}
4. After adjustment, pull the parking brake lever one rmnfil_I_~.O~=-

notch and verify that the parking brake warning
light illuminates. A
5. Verify that the rear brakes do not drag.
---~ DBR412ZWB002.
04-12-3
PARKING BRAKE LEVER REMOVAUINSTALLATION
dcf041244300w03
1. Remove the lower panel. (See 09-17-10 LOWER PANEL REMOVAUINSTALLATION.)

4. After installation, inspect the parking brake lever stroke. (See 04-12-3 PARKING BRAKE LEVER
INSPECTION.)
N·m { kgt·m, ft·lbf}

DBR412ZWB004
1 Parking brake switch connector 6 Parking brake switch

2 Clip 7 Clip and joint pin
3 Front parking brake cable 8 Cable connector
(See 04-12-5 PARKING BRAKE CABLE REMOVAU 9 Clip and joint pin
INSTALLATION [WL-3].) I.
INSTALLATION [WL-C (EXCEPT Hi-Rider)].) 11 Lever
INSTALLATION [WL-C (Hi-Rider), WE-C].)
13 Spring
4 Bolt and nut
14 Ratchet pawl
5 Parking brake lever component
04-12-4
15 Stopper 18 IGuide
16 Fork joint 19 Rod
17 Spring
PARKING BRAKE CABLE REMOVAUINSTALLATION [WL-3]

dcf04124441Ow01
1. Remove the fuel tank cover. (See 01-14A-S FUEL TANK REMOVAUINSTALLATION [WL-3].)
2. Remove the brake shoe (trailing shoe). (See 04-11-23 REAR BRAKE (DRUM) REMOVAUINSTALLATION.)
INSPECTION.)
15.68-21.54
{1.599-2.196,
11.57-15.88}
15.68-21.54
{1.599-2.196,
11.57-15.88}
--""::::::==:I;'l2::.....-- ~
DBR412ZWB005
1 Clip 6 Bracket
2 Bolt 7 Bolt
3 Spring 8 Clip
4 Front parking brake cable 9 Rear parking brake cable (left)
(See 04-12-6 Front Parking Brake Cable Removal 10 Rear parking brake cable (right)
Note.)
11 Grommet
5 Bolt
04-12-5
Front Parking Brake Cable Removal Note
1. Slide the clip installed to the cable connector in
the direction shown by the arrow.
2. Remove the end of the front parking brake cable
from the cable connector. CABLE
CONNECTER
\ 7 ' - - > , - - _ CLIP

DBR412ZWB008
PARKING BRAKE CABLE REMOVAL/INSTALLATION [WL-C 4x2 (EXCEPT Hi-Rider)]

dcf041244410w02
1. Remove the fuel tank cover. (See 01-14B-4 FUEL TANK REMOVAUINSTALLATION [WL-C, WE-C].)
INSPECTION.)
~
15.68-21.54
7 {1.599-2.196,
11.57-15.88}
@ - - - -......
15.68-21.54
{1.599-2.196,
~7 (Q
11.57-15.88}
15.68-21.54
{1.599-2.196,
11.57-15.88}
N·m {kgf.m, fj.lbf}
DBR412ZWB006
1 Nut 7 Bolt, nut

2 Bolt 8 Clip
3 Spring 9 Rear parking brake cable (left)
4 Front parking brake cable 10 Rear parking brake cable (right)
(See 04-12-6 Front Parking Brake Cable Removal 11 Grommet
Note.)
(See 04-12-7 Front Parking Brake Cable Installation
Note.)
5 Bolt
6 Bracket
04-12-6
Front Parking Brake Cable Installation Note
1. Install the front parking brake cable with the
spring installation area of the equalizer pointed
towards the inside of the vehicle.
"OF INSIDE
VEHICLE
DBR412ZWB009
PARKING BRAKE CABLE REMOVAUINSTALLATION [WL-C (Hi-Rider, 4x4), WE-C]

dcf041244410w03
1. Remove the fuel tank cover. (See 01-14B-4 FUEL TANK REMOVAL/INSTALLATION [WL-C, WE-C].)
INSPECTION.)
15.68-21.54
~ ~
{1.599-2.196,
11.57-15.88}
7
15.68-21.54
{1.599-2.196,
11.57-15.88}
7
7
15.68-21.54
{1.599-2.196,
~
11.57-15.88}
156H;)J(
R
1
"OF
{1.599-2.196,
INSIDE
11.5,5.88}
o
VEHICLE
1 1
~5
~7
~
1
"OF
1 INSIDE 6.9-9.8 N·m
15.68-21.54 {71-99 kgf·cm,
{1.599-2.196, 62-86 in.lbf}
VEHICLE
11.57-15.88}
N·m {kgf·m, It.lbf}
DBR412ZWB007
1 Clip 7 Bolt
2 Bolt 8 Spring
3 Spring 9 Clip
4 Bolt 10 Rear parking brake cable (left)
5 Bracket 11 Rear parking brake cable (right)
6 Front parking brake cable 12 Grommet
(See 04-12-6 Front Parking Brake Cable Removal
Note.)
(See 04-12-8 Front Parking Brake Cable Installation
Note.)
04-12-7
Front Parking Brake Cable Installation Note
1. Install the front parking brake cable with the
spring installation area of the equalizer pointed
towards the inside of the vehicle.
DBR412ZWB010
PARKING BRAKE SWITCH INSPECTION

dcf041266450w01
1. Disconnect the parking brake switch connector.

table.
parking brake switch.
0--0: Continuity
Terminal
Condition Body
A
ground
Parking brake lever pulled

B3E0412W006
Parking brake lever released
CHU0412W003
04-12-8
04-13B ANTILOCK BRAKE SYSTEM [4-WHEEL ANTI LOCK

ABS LOCATION INDEX [4W-ABS] ..... 04-13B-1 FRONT ABS WHEEL-SPEED SENSOR
ABS HU/CM SYSTEM INSPECTION INSPECTION ..................... 04-13B-9
[4W-ABS] . ....................... 04-13B-2 REAR ABS WHEEL-SPEED SENSOR
ABS HUlCM REMOVAUINSTALLATION REMOVAUINSTALLATION
[4W-ABS] . ....................... 04-13B-3 [4W-ABS (4x2 (EXCEPT Hi-Rider))] .. . 04-13B-10
ABS HUlCM INSPECTION REAR ABS WHEEL-SPEED SENSOR
[4W-ABS] . ....................... 04-13B-5 REMOVAUINSTALLATION
FRONT ABS WHEEL-SPEED SENSOR [4W-ABS (Hi-Rider, 4x4)] . .......... . 04-13B-11
REMOVAUINSTALLATION REAR ABS WHEEL-SPEED SENSOR
[4W-ABS (4x2 (EXCEPT Hi-Rider))] .. 04-13B-7 INSPECTION [4W-ABS] ............. 04-13B-11
FRONT ABS WHEEL-SPEED SENSOR G SENSOR REMOVAUINSTALLATION
REMOVAUINSTALLATION [4W-ABS] ....................... . 04-13B-12
[4W-ABS (Hi-Rider, 4x4)] ........... 04-13B-8 G SENSOR INSPECTION [4W-ABS] .... 04-13B-13
ABS LOCATION INDEX [4W-ABS]

dcf041300000w02
DBR413ZWB001
1 ABS HU/CM 3 Rear ABS wheel-speed sensor

(See 04-13B-2 ABS HU/CM SYSTEM INSPECTION (See 04-13B-10 REAR ABS WHEEL-SPEED
[4W-ABS]) SENSOR REMOVAUINSTALLATION [4W-ABS (4x2
(See 04-13B-3 ABS HUlCM REMOVAU (EXCEPT Hi-Rider))])
INSTALLATION [4W-ABS]) (See 04-13B-11 REAR ABS WHEEL-SPEED
(See 04-13B-5 ABS HU/CM INSPECTION [4W- SENSOR REMOVAUINSTALLATION [4W-ABS (Hi-
ABS]) Rider, 4x4)])
2 Front ABS wheel-speed sensor (See 04-13B-11 REAR ABS WHEEL-SPEED
(See 04-13B-7 FRONT ABS WHEEL-SPEED SENSOR INSPECTION [4W-ABS])
SENSOR REMOVAUINSTALLATION [4W-ABS (4x2 4 G sensor (Hi-Rider, 4x4)
(EXCEPT Hi-Rider))]) (See 04-13B-12 G SENSOR REMOVAU
(See 04-13B-8 FRONT ABS WHEEL-SPEED . INS1ALLATION [4W-ABS])
SENSOR REMOVAUINSTALLATION [4W-ABS (Hi- (See 04-13B-13 G SENSOR INSPECTION [4W-
Rider, 4x4)]) ABS])
(See 04-13B-9 FRONT ABS WHEEL-SPEED
SENSOR INSPECTION)
04-138-1
ABS HUlCM SYSTEM INSPECTION [4W-ABS]
dcf041300000w03
ABS Hydraulic Unit On-vehicle Inspection
Preparation
2. Turn the ignition switch to the ON position and verify that the ABS warning light goes out after approx. 3.0 s.
3. Turn the ignition switch off.
4. Jack up the vehicle and support it evenly on safety stands.
5. Shift to neutral.
6. Release the parking brake.
7. Verify that all four wheels rotate.
8. Rotate the inspected wheels by hand and verify there is no brake drag.
• If there is any brake drag, perform regular brake inspection.
• If there is no brake drag, perform ABS HU/CM operation inspection.
Operation inspection
1. Perform "Preparation".
2. Connect the current diagnostic tool to the DLC-2
connector.
3. Set up an active command mode inspection
according to the combination of commands
below.
DBR402ZTB003
Command name Command

Operation condition
PMP_MOTOR V_RF_OTL V_RF_INL transmission type
Brake pressure retention OFF OFF ON
Manual
Brake pressure reduction ON ON ON
The chart above shows an example of a right front wheel inspection.
Caution
• When operating the solenoid valve and pump motor using the active command mode, make sure
to keep the operation time within 10 s to prevent damaging the ABS HUICM.
Note
• When working with two people, one should press on the brake pedal, the other should attempt to rotate
the wheel being inspected.
4. Send the command while depressing on the brake pedal and attempting to rotate the wheel being inspected.
5. Performing the inspection above determines the following:
• The ABS HU/CM brake lines are normal.
• The ABS HU/CM hydraulic system is not significantly abnormal (including inside ABS HU/CM).
• The ABS HU/CM internal electrical parts (solenoid, motor and other parts) are normal.
• The ABS HU/CM output system wiring harnesses (solenoid valve, relay system) are normal.
However, the following items cannot be verified.
• Malfunction of ABS HU/CM input system wiring harnesses and parts
• Extremely small leakage in the ABS HU/CM internal hydraulic system
• Intermittent malfunction of the abov~ items
04-138-2
ANTILOCK BRAKE SYSTEM [4-WHEEL ANTI LOCK BRAKE SYSTEM (4W-ABS)]
ABS HUlCM REMOVAL/INSTALLATION [4W-ABS]
dcf04134375OW05
Caution
• The internal parts of the ABS HUlCM could be damaged if dropped. Be careful not to drop the ABS
HUICM. Replace the ABS HUlCM if it is subjected to an impact.

6-10
{62-101,54-88}
18.6-25.5
{1.9-2.6,
13.8-18.8}
16-22
{1.7-2.2,12-16}
~18.6-25.5
{1.9-2.6,
13.8-18.8}
mJ' 490259 770B N·m {kgf·m, ft·lbf}
DBR413ZWB002
1 Connector 4 Nut
(See 04-13B-4 Connector Removal Note.) 5 washer
(See 04-13B-4 Connector Installation Note.)
6 ABS HU/CM
2 Brake pipe
(See 04-13B-4 Brake Pipe Removal Note.)
7 Bushing (ABS HU/CM side)
(See 04-13B-4 Brake Pipe Installation Note) 8 Bushing (bracket side)
3 ABS HUlCM component 9 Bracket
04-138-3
Connector Removal Note
1. Rotate the lock lever in the direction of the arrow,
and remove the ABS HUlCM connector.
Brake Pipe Removal Note

1. Place an alignment mark on the brake pipe and
ABS HU/CM.
2. Apply protective tape to the connector to prevent
brake fluid from entering.
3. Remove the brake pipe.
Brake Pipe Installation Note

1. When install the brake pipe, align the marks made
before removal with the ABS HU/CM as shown in LF
the figure.
2. Tighten the brake pipe to the specified torque
using the SST (49 0259 770B).
RF
REAR
DBR413ZWB006
Connector Installation Note

1. After connecting the connector, rotate the lock
lever in the direction of the arrow to install the
ABS HU/CM connector.
DBR413ZWB004
04-138-4
ABS HUlCM INSPECTION [4W-ABS]
dcf041343750w06
1. Disconnect the ASS HU/CM connector.

3. Attach the tester lead to the ASS HU/CM harness side connector, then inspect voltage, continuity or resistance
according to the standard (reference value) on the table.
Standard (Reference Value)
ASS HUlCM WIRING HARNESS-SIDE CONNECTOR
DBR413ZWB017
Measured Measured terminal

Terminal Signal name Connected to Standard Inspection item(s)
item (measured condition)
Ground Continuity • Wiring harness (A-
A Ground point Continuity A-ground point
(ABS motor) detected ground point)
Power supply
B (ABS motor Battery Voltage Under any condition B+ • Wiring harness (B-
battery)
operation)
C
Power supply
Battery Voltage Under any condition B+ • Wiring harness
(solenoid) (C--battery)
D
Ground
Ground point Continuity D-ground point
Continuity • Wiring harness (D-
(ABS system) detected ground point)
LF wheel- E-LF ABS wheel- • Wiring harness (E-LF
LF ABS wheel- Continuity ABS wheel-speed
E speed sensor Continuity speed sensor
speed sensor detected sensor connector
(single) connector terminal A
terminal A)
LF wheel- F-LF ABS wheel- • Wiring harness (F-LF
LF ABS wheel- Continuity ABS wheel-speed
F speed sensor Continuity speed sensor
(ground) connector terminal B
terminal B)
LR wheel- G-LR ABS wheel- • Wiring harness (G-LR

LR ABS wheel- Continuity ABS wheel-speed
G speed sensor Continuity speed sensor
terminal B)
H - - - - - -
LR wheel- I-LR ABS wheel- • Wiring harness (I-LR
LR ABS wheel- Continuity ABS wheel-speed
I speed sensor Continuity speed sensor
(signal) connector terminal A
terminal A)
Power supply Ignition switch at ON B+ • Wiring harness (J-

J Ignition switch Voltage ignition switch)
(system)
Ignition switch is off. 1 V or less -
RR wheel- K-RR ABS wheel- • Wiring harness (K-RR
RR ABS wheel- Continuity ABS wheel-speed
K speed sensor Continuity speed sensor
terminal B)
RR wheel- L-RR ABS wheel- • Wiring harness (L-RR

RR ABS wheel- Continuity ABS wheel-speed
L speed sensor Continuity speed sensor
terminal A)
RF wheel- M-RF ABS wheel- • Wiring harness (M-RF

RF ABS wheel- Continuity ABS wheel-speed
M speed sensor Continuity speed sensor
terminal B)
04-138-5
Measured Measured terminal

Terminal Signal name Connected to Standard Inspection item(s)
item (measured condition)
N-brake switch
(Brake pedal B+
depressed) • Wiring harness (N-
N Brake switch Brake switch Voltage brake switch)
V-brake switch
(Brake pedal not 1 V or less
• Brake switch
depressed)
RFwheel- O-RF ABS wheel- • Wiring harness (O-RF
RF ABS wheel- Continuity ABS wheel-speed
0 speed sensor Continuity speed sensor
terminal A)
G sensor P-G sensor connector Continuity • Wiring harness (P-G
p' G sensor Continuity sensor connector
(signal) terminal B detected
terminal B)
On-board KLN terminal of Q-DLC-2 connector Continuity • Wiring harness (Q-
Q Continuity DLC-2 connector
diagnostic DLC-2 terminal KLN detected
terminal KLN)
R - - - - - -
S - - - - - -
T - - - - - -
U - - - - - -
G sensor V-G sensor connector Continuity • Wiring harness (V-G

V' G sensor Continuity sensor connector
(power supply terminal A detected
terminal A)
G sensor W-G sensor • Wiring harness (W-G
W'
(ground)
G sensor Continuity
connector terminal C
- sensor connector
terminal C)
X - - - - - -
Y - - - - - -
Z - - - - - -
* : Hi-Rider, 4x4
014-138-6
FRONT ABS WHEEL-SPEED SENSOR REMOVAUINSTALLATION [4W-ABS (4x2 (EXCEPT Hi-Rider))]
dcf041343720w01
1. When removing the ABS wheel-speed sensor on the right side, remove the washer tank installation bolts and
the connector, then move the washer tank to a place out of the way. (See 09-19-5 WINDSHIELD WASHER
TANK REMOVAUINSTALLATION.)
VIEW FROM LEFT SIDE
INSERT CLIP SURELY
II
19-25
{2.0-2.5,
15-18}
19-25
2 {2.0-2.5, 15-18}
DBR413ZWB008
IConnector 3 IFront ABS wheel-speed sensor

2 Bolt
04-138-7
FRONT ABS WHEEL-SPEED SENSOR REMOVAL/INSTALLATION [4W-ABS (Hi-Rider, 4x4)]
dcf041343720w02
1. When removing the ABS wheel-speed sensor on the right side, remove the washer tank installation bolts and
the connector, then move the washer tank to a place out of the way. (See 09-19-5 WINDSHIELD WASHER
TANK REMOVAL/INSTALLATION.)
VIEW FROM LEFT SIDE
INSERT CLIP SURELY

DBR413ZWB009
IConnector 3 IFront ABS wheel-speed sensor

2 Bolt
04-138-8
ANTI LOCK BRAKE SYSTEM [4-WHEEL ANTI LOCK BRAKE SYSTEM (4W-ABS)]
FRONT ABS WHEEL-SPEED SENSOR INSPECTION
dcf041343720w03
Visual Inspection
1. Remove the wheel and tire, and inspect the sensor for looseness and damage. Replace the sensor if
necessary.
Clearance Inspection
1. Inspect the clearance between the wheel-speed
sensor and the sensor rotor. ASS WHEEL-SPEED SENSOR
Clearance
~ CLEARANCE
0.3-1.1 mm {0.012-0.043 in}
• If not as specified, replace the defective

""Y~~
part(s). (ABS wheel-speed sensor, ABS
sensor rotor and steering knuckle etc.)
ASS SENSOR ROTOR
DBR413ZWB010
1. Disconnect the ABS wheel-speed sensor connector.
2. Inspect the resistance at the ABS wheel-speed sensor.
• If not as specified, replace the ABS wheel-speed sensor.
Resistance
1.2-1.6 kilohm
Voltage Inspection
1. Jack up the vehicle on level ground and support it evenly on safety stands.
3. Inspect each sensor by rotating each wheel one revolution per second.
• If not as specified, replace the ABS wheel-speed sensor.
Voltage
0.15-1.2 V (AC)
Voltage Pattern Inspection

3. Using an oscilloscope, inspect voltage pattern for
distortion and noise by rotating each wheel. + HIGH SPEED
• If there is distortion or noise, inspect the ABS
sensor rotor.
LOW SPEED
DBR413ZWB011
04-138-9
REAR ABS WHEEL-SPEED SENSOR REMOVAL/INSTALLATION [4W-ABS (4x2 (EXCEPT Hi-Rider))]
dcf041343710w03

7.8-10.8 N·m
{80-110 kgf.cm,
70-95 in·lbf}
2
19-25
{1.9-2.6,
14-18}
{80-110 kgf·cm,
70-95 in·lbf} N·m {kgf.m, ft·lbf}
DBR413ZWB012
I Connector 3 IRear ABS wheel-speed sensor

2 Bolt
04-138-10
REAR ABS WHEEL-SPEED SENSOR REMOVAL/INSTALLATION [4W-ABS (Hi-Rider, 4x4)]
dcf04134371Ow04
19-25
{1.9-2.6,
14-18}
DBR413ZWB013
IConnector 3 IRear ABS wheel-speed sensor

2 Bolt
REAR ABS WHEEL-SPEED SENSOR INSPECTION [4W-ABS]

dcf04134371OwOS
Visual Inspection
1. Inspect the sensor for looseness and damage. Replace the sensor if necessary.
Clearance Inspection
1. Remove the ASS wheel-speed sensor.
.rD=
2. Measure the length A and S shown in the figure
using vernier calipers.
3. Subtract S from A then verify the clearance
between the wheel-speed sensor and the sensor
rotor.
~
Clearance
0.3-1.1 mm {0.012-0.043 in}
• If not as specified, replace the defective

ASS SENSOR ROTOR \
part(s}. (ASS wheel-speed sensor, ASS
sensor rotor, rear axle shaft and rear axle
DBR413ZWB014
housing etc.)
04-138-11
1. Disconnect the ASS wheel-speed sensor connector.
2. Inspect the resistance at the ASS wheel-speed sensor.
• If not as specified, replace the ASS wheel-speed sensor.
Resistance
1.2-1.6 kilohm
Voltage Inspection
1. On level ground, jack up the vehicle and support it evenly on safety stands.
3. Inspect each sensor by rotating each wheel one revolution per second.
• If not as specified, replace the ASS wheel-speed sensor.
Voltage
0.15-1.2 V (AC)
Voltage Pattern Inspection

3. Using an oscilloscope, inspect voltage pattern for
distortion and noise by rotating each wheel. + HIGH SPEED
• If there is distortion or noise, inspect the ASS
sensor rotor.
LOW SPEED
DBR413ZWB011
G SENSOR REMOVAUINSTALLATION [4W-ABS]

dcf041343770w01
Caution
• Be careful and do not allow the combined sensor to fall. If by chance it is subjected to strong
impact, replace it.
1. Slide the RH front seat fully backward.

2. Remove in the order indicated in the table. 7.8-10.S N·m {SO-l10 kgf.cm, 70-95 in·lbf}
)
1 Connector
2 G sensor and bracket
3 G sensor
4.2-S.2 N·m {43-S3 kgf·cm, 3S-54 in·lbf}

DBR,!13ZWB015
04-138-12
G SENSOR INSPECTION [4W-ABS]
dcf041343770w02
1. Connect the connector.
2. Turn ignition switch (engine switch) on, and verify the voltage between terminals A and B under the following
conditions.
• If not within the specification, replace the G sensor.
(1) Horizontal ,---------::---------------,
Voltage
2.4-2.6 V
DBR413ZWB016
(2) Facing up (inclined 90 from horizontal)

0
Voltage
1.3-1.7 V
ABR6916W007.
(3) Facing down (declined 90 from horizontal)

0
Voltage
3.3-3.7 V
ABR6916W010
04-138-13
TECHNICAL DATA

BRAKE TECHNICAL DATA .......... 04-50-1
BRAKE TECHNICAL DATA

dcf04500000OW01
Item Specification
Brake fluid type SAE J1703, FMVSS 116 DOT-3
Brake pedal height 214-219 mm {8A3-8.62 in}
Standard pedal play 3.0-8.0 mm {0.12-0.31 in}
Standard pedal-to-floor clearance 105 mm {4.14 in} or more
Power brake unit fluid pressure when pedal depressed
at 200 N {20 kgf, 45 Ibf} At 0 kPa {O mmHg, 0 inHg}: 593 kPa {6.1 kgf/cm 2, 87 psi} or more
Power brake unit fluid pressure when pedal depressed At 67 kPa {500 mmHg, 20 inHg}: 6,950 kPa {71 kgf/cm2, 1,008 psi} or
at 200 N {20 kgf, 45 Ibf} more
Minimum front disc pad thickness 2.0 mm {0.079 in} min.
Minimum front disc plate thickness
Hi-Rider, 4x4: 26.0 mm {1.03 in}
Minimum front disc plate thickness after machining 4x2 (except Hi-Rider): 22.8 mm {0.898 in}
using a brake lathe on-vehicle Hi-Rider, 4x4: 26.8 mm {1.06 in}
Front disc plate runout limit 0.05 mm {0.002 in} max.
Minimum rear brake lining thickness 1.0 mm {0.04 in}
4x2 (except Hi-Rider): 271.5 mm {1 0.68 in}
Maximum rear brake drum diameter
Hi-Rider, 4x4: 296.5 mm {11.67 in}
Parking brake lever stroke when pulled at 98 N {10
1-7 notches
kgf,22Ibf}
Load sensing proportioning valve (LSPV) fluid pressure

Front wheel cylinder fluid pressure Rear wheel cylinder
Type
(kPa {kgf/cm 2 , psi}) (kPa {kgf/cm 2 , psi})
4,900 {50, 711} 2,250-2,850 {23-29, 327-413}
Without 4W-ABS
4x2 (except Hi- 9,800 {1 00, 1,421} 3,130-3,930 {32-40, 454-569}
Rider) 4,900 {50, 711} 2,910-3,710 {30-37, 423-538}
With 4W-ABS
9,800 {100, 1,421} 4,970-6,170 {51-62, 721-894}
4,900 {50, 711} 2,250-2,850 {23-29, 327-413}
Without 4W-ABS
9,800 {100, 1,421} 3,130-3,930 {32-40, 454-569}
Hi-Rider, 4x4
4,900 {50, 711} 2,650-3,450 {28-35, 385-500}
With 4W-ABS
9,800 {100, 1,421} 4,700-5,900 {48-60, 682-855}
04-50-1
SERVICE TOOLS
04-60 SERVICE TOOLS

BRAKES SST ..................... 04-60-1
BRAKES SST
dcf046000000w01
490259770B 49 U043 OAOA 49 U043 004A
Flare nut Oil pressure Oil pressure.

wrench gauge set gauge
(Part of 49
CI U0430AOA)
CI
49 U043 005 49 U043 006 490221 600C
Joint Hose Disc brake

(Part of 49 (Part of 49 expand tool
U0430AOA) U0430AOA)
49 T033 001A WDS
Disc brake
piston stopper
~------~------~------~mI
04-60-1
ON-BOARD DIAGNOSTIC AUTOMATIC TRANSMISSION

[SRSSS] . . . . . . . . . . . . . . . . . OS-02 SHIFT MECHANISM ..•..... OS-14
SYMPTOM TROUBLESHOOTING TECHNICAL DATA[SRSSS] ... OS-SO
[SRSSS] . . . . . . . . . . . . . . . .. OS-03 SERVICE TOOLS[SRSSS] .... OS-60
AUTOMATIC TRANSMISSION
[SRSSS] . . . . . . . . . . . . . . . . . OS-13
05-02 ON-BOARD DIAGNOSTIC [5R55S]

AUTOMATIC TRANSMISSION DTC P074S, P0748, P0960,
CONTROL SYSTEM P0962,P0963[SRSSS] ......•....... OS-02-22
WIRING DIAGRAM [SRSSS] ......... OS-02-2 DTC P07S0, P07S3 [SRSSS] ••......•.. OS-02-24
FOREWORD [SRSSS] .....•••......• OS-02-3 DTC P07SS, P07S7, P07S8 [SRSSS] '" .OS-02-26
AUTOMATIC TRANSMISSION DTC P0760, P0762, P0763 [SRSSS] •... OS-02-28
ON-BOARD DIAGNOSTIC DTC P076S, P0768 [SRSSS] .•....•.•.. OS-02-30
FUNCTION [SRSSS] .•....••..••... OS-02-3 DTC P077S, P0778, P0964,
AFTER REPAIR PROCEDURE P0966,P0967[SRSSS] ..••.•..•....• OS-02-32
[SRSSS] ......••...•..•.•........ OS-02-4 DTC P0791, P0794 [SRSSS] .•..•.•.... OS-02-34
DTC TABLE [SRSSS] ...•..••.....•.. OS-02-S DTC P079S, P0798, P0968,
DTC P06S7, P06S8 [SRSSS] ....•.•... OS-02-7 P0970,P0971 [SRSSS] ...........•.. OS-02-36
DTC P070S, P0708, P1702, DTC P163S [SRSSS] .••.....•....•... OS-02-38
P1704, P170S [SRSSS] •.. '.o •••••••• OS-02-9 DTC P1700 [SRSSS] .........•..•.... OS-02-38
DTC P0711, P0712, P0713 [SRSSS] ••.. OS-02-13 DTC P1711 [SRSSS] ••••...••.•..••.. OS-02-39
DTC P071S, P0717, P0718 [SRSSS] .••• OS-02-1S DTC P1780 [SRSSS] ....•••.....•.... OS-02-40
DTC P0720, P0721 , P0722 [SRSSS] . . . . OS-02-17 DTC P1783 [SRSSS] ...•.....•....•.. OS-02-42
DTC P0731 , P0732, P0733, DTC U0100, U0297 [SRSSS] .•.•.•.... OS-02-43
P0734, P073S [SRSSS] ...••••.•...• OS-02-19 PID/DATA MONITOR INSPECTION
DTC P0740, P0741 , P0742, [SRSSS] .....•..•...•...•.•....... OS-02-4S
P0743, P0744 [SRSSS] ............. OS-02-20
05-02-1
AUTOMATIC TRANSMISSION CONTROL SYSTEM WIRING DIAGRAM [SRSSS]
id0502c1811000
IG1 B+ B+
TCM
AT RELAY
TCC CONTROL SOLENOID

OTHER
MODULE
SHIFT SOLENOID A
SHIFT SOLENOID B
4x4
CONTROL SHIFT SOLENOID C
MODULE
SHIFT SOLENOID D
IG1

J J-------'
MJ-------'
INSTRUMENT
CLUSTER
TR1
TR2
TR4
OSS SENSOR
ISS SENSOR
TSS SENSOR
arnffwOOOO 1941
05-02-2
ON-BOARD DIAGNOSTIC [5R55S1
FOREWORD [5R55S]
id0502c1800200
• When the customer reports a vehicle malfunction, inspect the malfunction indicator lamp (MIL) indication, OlD
OFF indicator light flashing, and TCM memory for diagnostic trouble code (DTC), then diagnose the
malfunction according to following flowchart.
If the DTC exists, diagnose the applicable DTC. (See 05-02-5 DTC TABLE [5R55S].)
If the DTC does not exist and the MIL does not illuminate, and the OlD OFF indicator light flashes, diagnose
the applicable symptom troubleshooting. (See05-03-5 SYMPTOM TROUBLESHOOTING ITEM TABLE
[5R55S].)
VALIDATE CONCERN
WARNING LIGHT' NO WARNING LIGHT'

ON IFLASHING WITH SYMPTOM
• INSPECT DTC
INSPECT FOR
• IGNITION ON TEST, IDLING
PRIORITIZED DTC
TEST
DTC
NODTC
DIAGNOSE BY DTC DIAGNOSE BY SYMPTOM

(ON-BOARD DIAGNOSTIC) (SYMPTOM TROUBLESHOOTING)
• DTCTABLE 1. DIAGNOSTIC INDEX
• DTC TROUBLESHOOTING FLOW 2. QUICK DIAGNOSIS CHART
3. SYMPTOM TROUBLESHOOTING
*: Malfunction Indicator Lamp (MIL), OlD OFF indicator light
AUTOMATIC TRANSMISSION ON-BOARD DIAGNOSTIC FUNCTION [5R55S]

id0502c1811100
DTC Reading Procedure

1. Perform necessary vehicle preparation and visual inspection.
2. Connect the IDS/PDS to the DLC-2. ,.---------------------,
items from the initial screen of the IDS/PDS.
• When using the IDS (laptop PC)
3. Select "Modules".
4. Select "TCM".
• When using the PDS (Pocket PC)
2. Select "TCM".
absggw00000987
screen.
5. After completion of repairs, clear all DTCs stored in the TCM. (See 05-02-4 AFTER REPAIR PROCEDURE
[5R55S].)
05-02-3
AFTER REPAIR PROCEDURE [5R55S]
id0502c1800400
Caution
• After repairing a malfunction, perform this procedure to verify that the malfunction has been
corrected .
• When this procedure is carried out, be sure to drive the vehicle at lawful speed and pay attention
to other vehicles.
1. Connect the IDS/PDS to the DLC-2.

items from the initial screen of the IDS/PDS .
4. Select "TCM".
2. Select "TCM".
absggw00000987
IDS/PDS screen.
4. Press the clear button on the DTC screen to clear the DTC.
5. Verify that no DTCs are displayed.
6. Verify that the ATF level is normal.
,7. Turn the OlD OFF switch on (OlD OFF indicator illuminates) and gradually accelerate vehicle speed to 64 kml
h {40 mph}.
• Verify that the transmission shifts to 4GR, and maintain the vehicle speed and acceleration pedal opening
angle for 15 s or more.
8. Turn the OlD OFF switch off (O/D OFF indicator turns off) and accelerate the vehicle speed to 80 'km/h {50
mph}.
• Verify that the transmission shifts to 5GR, and maintain the vehicle speed and acceleration pedal opening
angle for 15 s or more.
9. Decelerate using light brake pedal force (Brake light illuminates). Maintain this condition for 5 s or more.
10. Stop the vehicle for approx. 20 s.
11. Repeat Steps 7-10 five times.
12. Gradually slow down and stop the vehicle.
13. Make sure that the repaired DTC does not recur.
05-02-4
DTC TABLE [5R55S]
id0502c1800500
DTC No. Condition Page

P0657 Solenoid valve power supply circuit open (See 05-02-7 DTC P0657, P0658 [5R55S].)
P0658 Solenoid valve power supply circuit voltage low (See 05-02-7 DTC P0657, P0658 [5R55S].)
Digital transmission range (TR) sensor circuit malfunction (See 05-02-9 DTC P0705, P0708, P1702, P1704,
P0705
(invalid bit pattern) P1705 [5R55S].)
Digital transmission range (TR) sensor circuit malfunction (See 05-02-9 DTC P0705, P0708, P1702, P1704,
P0708
(TR3A circuit open) P1705 [5R55S].)
Transmission fluid temperature (TFT) sensor malfunction
P0711 (See 05-02-13 DTC P0711, P0712, P0713 [5R55S].)
(ATF temperature no change)
Transmission fluid temperature (TFT) sensor circuit
P0712 (See 05-02-13 DTC P0711, P0712, P0713 [5R55S].)
malfunction (short to ground)
Transmission fluid temperature (TFT) sensor circuit
P0713 (See 05-02-13 DTC P0711, P0712, P0713 [5R55S].)
malfunction (open circuit)
P0715 Turbine shaft speed (TSS) sensor malfunction (See 05-02-15 DTC P0715, P0717, P0718 [5R55S].)
P0717 Turbine shaft speed (TSS) sensor signal is not input (See 05-02-15 DTC P0715, P0717, P0718 [5R55S].)
P0718 Turbine shaft speed (TSS) sensor signal noise (See 05-02-15 DTC P0715, P0717, P0718 [5R55S].)
P0720 Output shaft speed (OSS) sensor malfunction (See 05-02-17 DTC P0720, P0721 , P0722 [5R55S].)
P0721 Output shaft speed (OSS) sensor signal noise (See 05-02-17 DTC P0720, P0721 , P0722 [5R55S].)
P0722 Output shaft speed (OSS) sensor signal is not input (See 05-02-17 DTC P0720, P0721 , P0722 [5R55S].)
(See 05-02-19 DTC P0731 , P0732, P0733, P0734,
P0735 [5R55S].)
(See 05-02-19 DTC P0731 , P0732, P0733, P0734,
P0735 [5R55S].)
(See 05-02-19 DTC P0731 , P0732, P0733, P0734,
P0735 [5R55SJ.)
(See 05-02-19 DTC P0731 , P0732, P0733, P0734,
P0735 [5R55S].)
(See 05-02-19 DTC P0731 , P0732, P0733, P0734,
P0735 [5R55S].)
Torque converter clutch (TCC) control solenoid circuit (See 05-02-20 DTC P0740, P0741 , P0742, P0743,
P0740
malfunction (open circuit) P0744 [5R55S].)
P0741
malfunction (stuck off) P0744 [5R55S].)
P0742
malfunction (stuck on) P0744 [5R55S].)
P0743
malfunction (open or short circuit) P0744 [5R55S].)
P0744
malfunction (short to power) P0744 [5R55S].)
(See 05-02-22 DTC P0745, P0748, P0960, P0962,
P0745 Pressure control solenoid A malfunction (low pressure)
P0963 [5R55S].)
Pressure control solenoid A circuit malfunction (non- (See 05-02-22 DTC P0745, P0748, P0960, P0962,
P0748
operation) P0963 [5R55S].)
P0750 Shift solenoid A circuit malfunction (open or short circuit) (See 05-02-24 DTC P0750, P0753 [5R55S].)
P0753 Shift solenoid A circuit malfunction (open or short circuit) (See 05-02-24 DTC P0750, P0753 [5R55S].)
P0755 Shift solenoid B circuit malfunction (open or short circuit) (See 05-02-26 DTC P0755, P0757, P0758 [5R55S].)
P0757 Shift solenoid B malfunction (stuck on) (See 05-02-26 DTC P0755, P0757, P0758 [5R55S].)
P0758 Shift solenoid B circuit malfunction (open or short circuit) (See 05-02-26 DTC P0755, P0757, P0758 [5R55S].)
P0760 Shift solenoid C circuit malfunction (open or short circuit) (See 05-02-28 DTC P0760, P0762, P0763 [5R55S].)
P0762 Shift solenoid C malfunction (stuck on) (See 05-02-28 DTC P0760, P0762, P0763 [5R55S].)
P0763 Shift solenoid C circuit malfunction (open or short circuit) (See 05-02-28 DTC P0760, P0762, P0763 [5R55S].)
P0765 Shift solenoid 0 circuit malfunction (open or short circuit) (See 05-02-30 DTC P0765, P0768 [5R55S].)
P0768 Shift solenoid 0 circuit malfunction (open or short circuit) (See 05-02-30 DTC P0765, P0768 [5R55S].)
(See 05-02-32 DlC P0775 , P0778, P0964, P0966,
P0775 Pressure control solenoid B malfunction (low pressure)
P0967 [5R55S].)
Pressure control solenoid B circuit malfunction (non- (See 05-02-32 DTC P0775, P0778, P0964, P0966,
P0778
P0791 Intermediate shaft speed (ISS) sensor malfunction (See 05-02-34 DTC P0791 , P0794 [5R55S].)
05-02-5
DTC No. Condition Page

P0794 Intermediate shaft speed (ISS) sensor signal noise (See 05-02-34 DTC P0791 , P0794 [5R55S].)
(See 05-02-36 DTC P0795, P0798, P0968, P0970,
P0795 Pressure control solenoid C malfunction (low pressure)
P0971 [5R55S].)
Pressure control solenoid C circuit malfunction (non- (See 05-02-36 DTC P0795, P0798, P0968, P0970,
P0798
Pressure control solenoid A circuit malfunction (open (See 05-02-22 DTC P0745, P0748, P0960, P0962,
P0960
circuit) P0963 [5R55S].)
Pressure control solenoid A circuit malfunction (short to (See 05-02-22 DTC P0745, P0748, P0960, P0962,
P0962
ground) P0963 [5R55S].)
Pressure control solenoid A circuit malfunction (short to (See 05-02-22 DTC P0745, P0748, P0960, P0962,
P0963
power supply) P0963 [5R55S].)
Pressure control solenoid B circuit malfunction (open (See 05-02-32 DTC P0775, P0778, P0964, P0966,
P0964
Pressure control solenoid B circuit malfunction (short to (See 05-02-32 DTC P0775, P0778, P0964, P0966,
P0966
ground) P0967 [5R55S].)
Pressure control solenoid B circuit malfunction (short to (See 05-02-32 DTC P0775, P0778, P0964, P0966,
P0967
Pressure control solenoid C circuit malfunction (open (See 05-02-36 DTC P0795, P0798, P0968, P0970,
P0968
Pressure control solenoid C circuit malfunction (short to (See 05-02-36 DTC P0795, P0798, P0968, P0970,
P0970
ground) P0971 [5R55S].)
Pressure control solenoid C circuit malfunction (short to (See 05-02-36 DTC P0795, P0798, P0968, P0970,
P0971
P1635 Tire/axle ratio out of acceptable range (See 05-02-38 DTC P1635 [5R55S].)
P1700 Transmission indeterminate malfunction (See 05-02-38 DTC P1700 [5R55S].)
(See 05-02-9 DTC P0705, P0708, P1702, P1704,
P1702 Digital transmission range (TR) sensor circuit intermittent
P1705 [5R55S].)
Digital transmission range (TR) sensor circuit not (See 05-02-9 DTC P0705, P0708, P1702, P1704,
P1704
indicating P or N position during on-board diagnostic P1705 [5R55S].)
Digital transmission range (TR) sensor circuit not (See 05-02-9 DTC P0705, P0708, P1702, P1704,
P1705 P1705 [5R55S].)
indicating P or N position during on-board diagnostic
P1711 ATF temperature out of on-board diagnostic range (See 05-02-39 DTC P1711 [5R55S].)
P1780 OlD OFF switch circuit malfunction (open or short circuit) (See 05-02-40DTC P1780 [5R55S].)
P1783 ATF overheating (See 05-02-42 DTC P1783 [5R55S].)
U0100 Communication error to PCM (See 05-02-43 DTC U0100, U0297 [5R55S].)
U0294 Communication error to PCM (See 05-02-43 DTC U0100, U0297 [5R55S].)
i.
05-02-6
DTC P0657, P0658 [5R55S]
id0502c1814400
DTC P06S7 Solenoid valve power supply circuit open

DTC P06S8 Solenoid valve power supply circuit voltage low
DETECTION • P0657: Open circuit in circuit between solenoid valve and TCM
CONDITION • P0658: Short circuit in circuit between solenoid valve and TCM
• Short to ground in wiring harness between AT connector terminal I (wiring harness-side) and TCM terminal
CK (wiring harness-side).
POSSIBLE • Open circuit in wiring harness between AT connector terminal I (wiring harness-side) and TCM terminal CK
CAUSE (wiring harness-side).
• Damaged connector between shift AT connector and TCM.
• TCM malfunction.
TCM AT AT CONNECTOR WIRING

@cv SOLENOID VALVE
TCM WIRING HARNESS-SIDE

CONNECTOR
-
A E I M 0 U Y AC AG AK AO AS AW BA BE BI BM BO BU BY CC CG -,...-
CK CN
B F J N R V Z AD AH AL AP AT AX BB BF BJ BN BR BV BZ CD CH
i~
-r-
CLpO
C G K 0 S W AA AE AI AM AO AU AY BC BG BK BO BS BW CA CE CI -r-
PMCP
0 H· L P T X AB AF AJ AN AR AV AZ BD BH BL BP BT BX CB CF CJ '--'--
'--
05-02-7
recorded?
3 INSPECT AT CONNECTOR FOR POOR Yes Go to the next step.
CONNECTION No Repair or replace the connector and/or terminals, then go
• Turn the engine switch to the LOCK position. to Step 8.
• Inspect AT connector connection.
• Disconnect the AT connector.
• Is the connection normal?
4 INSPECT POWER SUPPLY CIRCUIT Yes Go to Step 8.
(engine off).
• Inspect voltage at AT connector terminal H
(wiring harness-side).
• the voltage approx. 12 V?
Is
5 INSPECT TCM CONNECTOR FOR POOR Yes Go to the next step.
CONNECTION No Repair or replace connector and/or terminals, then go to
• Turn the engine switch to the LOCK position. Step 8.
• Disconnect the TCM connector.
6 INSPECT SOLENOID POWER SUPPLY CIRCUIT Yes Go to the next step.
FOR OPEN CIRCUIT No Repair or replace the wiring harness, then go to Step 8.
• Inspect for continuity between the TCM
terminal CK (wiring harness-side) and the AT
connector terminal I (wiring harness-side).
• Is there continuity between terminals?
7 INSPECT SOLENOID POWER SUPPLY CIRCUIT Yes Repair or replace the wiring harness, then go to the Step 8.
• Inspect continuity between AT connector
terminal H (wiring harness-side) and body
ground.
8 VERIFY TROUBLESHOOTING OF DTC P0657 Yes Replace the TCM, then go to the next step.
OR P0658 COMPLETED (See 05-13-44 TCM REMOVAUINSTALLATION [5R55S].)
• Make sure to reconnect all the disconnected No Go to the next step.
connectors.
• Clear the DTC from memory using the IDS/
PDS.
(See 05-02-4 AFTER REPAIR PROCEDURE
[5R55S].)
9 VERIFY DTCS Yes Go to the applicable DTC inspection.
• Are DTCs except for P0657 and P0658 output? (See 05-02-5 DTC TABLE [5R55S].)
05-02-8
DTC P0705, P0708, P1702, P1704, P1705 [5R55S]
idOS02c1814S00
DTC P070S Digital transmission range (TR) sensor circuit malfunction (invalid bit pattern)
DTC P070S Digital transmission range (TR) sensor circuit malfunction (TR3A circuit open)
DTC P1702 Digital transmission range (TR) sensor circuit intermittent
Digital transmission range (TR) sensor circuit not indicating P or N position during on-board
DTC P1704
diagnostic
DTC P170S
diagnostic
• P0705: Open circuit or short to ground in wiring harness between digital TR sensor terminal and TCM
terminal or in digital TR sensor internal circuit (invalid bit pattern)
• P070S: Open circuit in wiring harness between digital TR sensor and TCM terminal or in digital TR sensor
DETECTION
internal circuit (TR3 circuit)
CONDITION
• P1702: TCM cannot detect a signal from digital TR sensor
• P1704: PID TR_D not indicating P or N position, digital TR sensor or selector cable misalignment
• P1705: On-board diagnostic not performed in P or N position
• Digital TR sensor or selector cable misadjustment
• Short to ground in wiring harness between digital TR sensor terminal G and TCM terminal AX
• Short to ground in wiring harness between digital TR sensor terminal E and TCM terminal BY
• Short to ground in wiring harness between digital TR sensor terminal C and TCM terminal BU
• Short to ground in wiring harness between digital TR sensor terminal A and TCM terminal CA
• Short to ground in wiring harness between digital TR sensor terminal I and TCM terminal BH
• Open circuit in wiring harness between digital TR sensor terminal G and TCM terminal AX
• Open circuit in wiring harness between digital TR sensor terminal E and TCM terminal BY
POSSIBLE
• Open circuit in wiring harness between digital TR sensor terminal C and TCM terminal BU
CAUSE
• Open circuit in wiring harness between digital TR sensor terminal A and TCM terminal CA
• Open circuit in wiring harness between digital TR sensor terminal I and TCM terminal BH
• Short to power supply in wiring harness between digital TR sensor terminal G and TCM terminal AX
• Short to power supply in wiring harness between digital TR sensor terminal E and TCM terminal BY
• Short to power supply in wiring harness between digital TR sensor terminal C and TCM terminal BU
• Short to power supply in wiring harness between digital TR sensor terminal A and TCM terminal CA
• Short to power supply in wiring harness between digital TR sensor terminal I and TCM terminal BH
• Damaged connectors between digital TR sensor and TCM
• TCM malfunction
05-02-9
DTe P0705 Digital transmission range (TR) sensor circuit malfunction (invalid bit pattern)
DTe P0708 Digital transmission range (TR) sensor circuit malfunction (TR3A circuit open)
DTe P1702 Digital transmission range (TR) sensor circuit intermittent
DTe P1704
diagnostic
DTe P1705
diagnostic
DIGITAL TR SENSOR WIRING DIGITAL TR SENSOR @ (J) TCM

® ®@!@ @
TR3A
®@!@
®@!@
AT CONNECTOR WIRING
HARNESS-SIDE CONNECTOR ®@!@
®@!@

CONNECTOR
- A E I M Q U Y AC AG AK AO AS AW BA BE BI BM BQ BU BY CC CG .....--
CK CN
r-- -
~
B F J N R V Z AD AH AL AP AT AX BB BF BJ BN BR BV BZ CD CH
CL CO
C G K 0 S W AA AE AI AM AQ AU AY BC BG BK BO BS BW CA CE CI r-- -
CM CP
0 H L P T X AB AF AJ AN AR AV AZ BD BH BL BP BT BX CB CF CJ '---
-
05-02--10
recorded?
3 VERIFY DIGITAL TR SENSOR ALIGNMENT Yes Connect the selector cable to the manual lever, then go to
• Select the N position. the next step.
• Turn the engine switch to the LOCK position. No Adjust the digital TR sensor, then go to Step 12.
• Disconnect the selector cable from the manual (See 05-13-24 DIGITAL TRANSMISSION RANGE (TR)
lever. SENSOR ADJUSTMENT [5R55S].)
• Verify that the SST (307-351 (49 UN30 7351))
fits in the appropriate slots of digital TR sensor.
• Is the digital TR sensor correctly adjusted?
4 VERIFY SELECTOR CABLE ADJUSTMENT Yes Go to the next step.
• Turn the engine switch to the ON position. No Adjust the selector cable, then go to Step 12.
• Verify that the selector cable is correctly (See 05-14-2 SELECTOR CABLE ADJUSTMENT.)
adjusted.
(See 05-14-2 SELECTOR CABLE
ADJUSTMENT.)
• Is the selector cable is correctly adjusted?
5 INSPECT ELECTRICAL SYSTEM OPERATION Yes Go to Step 12.
• Connect the IDS/PDS to DLC-2. No Go to the next step.
• Access TR_D and TR_V PIDs.
• Move the selector lever into each range and
position (P, R, N, D, 3, 2, 1).
• Observe the PIDs, TR D and TR V (vehicle-
dependent) while wiggling wiring harness,
tapping on sensor or driving the vehicle.
- Use PIDs TR_D for DTCs P0705, P1704
and P1705.
- Use PIDs TR_V for DTC P0708.
• Are the PIDs within the specification?
6 INSPECT DIGITAL TR SENSOR CONNECTOR Yes Go to the next step.
FOR POOR CONNECTION No Repair or replace connector and/or terminal, then go to
• Disconnect the digital TR sensor connector.
7 INSPECT DIGITAL TR SENSOR Yes Go to the next step.
• Inspect the digital TR sensor. No Replace the digital TR sensor, then go to Step 12.
(See 05-13-20 DIGITAL TRANSMISSION (See 05-13-22 DIGITAL TRANSMISSION RANGE (TR)
RANGE (TR) SENSOR INSPECTION SENSOR REMOVAUINSTALLATION [5R55S].)
[5R55S].)
• Is digital TR sensor normal?
• Disconnect the TCM connector. to Step 12.
9 INSPECT DIGITAL TR SENSOR CIRCUIT FOR Yes Repair or replace the wiring harness, then go to Step 12.
SHORT TO GROUND No Go to the next step.
• Inspect continuity between digital TR sensor
terminals (wiring harness-side) and body
ground.
- G and body ground
- E and body ground
- C and body ground
- A and body ground
- I and body ground
05-02-11

10 INSPECT DIGITAL TR SENSOR CIRCUIT FOR Yes Go to the next step.
SHORT TO POWER SUPPLY No Repair or replace the wiring harness, then go to Step 12.
(engine off).
• Inspect the voltage at digital TR sensor
terminals G, E, C, A and I (wiring harness-
side).
• Is the voltage 0 V?
11 INSPECT DIGITAL TR SENSOR CIRCUIT FOR Yes Go to the next step.
OPEN CIRCUIT No Repair or replace the wiring harness, then go to the next
• Inspect the following digital TR sensor step.
terminals (wiring harness-side) and TCM
-G and AX
-E and BY
-C and BU
-Aand CA
- I and BH
12 VERIFY TROUBLESHOOTING OF DTC P0705, Yes Replace the TCM, then go to the next step.
P070S, P1702, P1704 OR P1705 COMPLETED (See 05-13-44 TCM REMOVAUI NSTALLATION [5R55S].)
connectors.
• Clear the DTC from the memory using the IDS/
PDS.
[5R55SJ.)
• Are DTCs except for P0705, P0708, P1702, (See 05-02-5 DTC TABLE [5R55S].)
P1704 and P1705 output? No DTC troubleshooting completed.
05-02-12
DTC P0711, P0712, P0713 [5R55S]
id0502c1814600
DTC P0711 Transmission fluid temperature (TFT) sensor malfunction (ATF temperature no change)
DTC P0712 Transmission fluid temperature (TFT) sensor circuit malfunction (short to ground)
DTC P0713 Transmission fluid temperature (TFT) sensor circuit malfunction (open circuit)
• P0711: ATF temperature signal continually reading cold or hot
DETECTION
• P0712: TeM detects that ATF signal output from ATF sensor is 1570 C {315° F} or more
CONDITION
• P0713: TeM detects ATF signal from ATF sensor is -40° C {-40° F} or less
• TFT sensor malfunction
• Short to ground in wiring harness between AT connector terminal K and TeM terminal AY
• Short to ground in wiring harness between AT connector terminal Land TeM terminal BH
POSSIBLE
• Open circuit supply in wiring harness between AT connector terminal K and TeM terminal AY
CAUSE
• Open circuit supply in wiring harness between AT connector terminal Land TeM terminal BH
• Damaged connectors between AT connector and TeM
• TeM malfunction
AT CONNECTOR WIRING AT TCM

®
TFT SENSOR
® @cv
' - - - - - - { L 17T------(E{):IHl

CONNECTOR
r--
A E I M Q U Y AC AG AK AO AS ~W BA BE BI BM BQ BU BY CC CG -r--
CK CN
I~
B F J N R V Z AD AH AL AP AT AX BB BF BJ BN BR BV BZ CD CH - r-
CL CO
C G K 0 S W AA AE AI AM AQ AU AY BC BG BK BO BS BW CA CE CI - r-
CM CP
D H L P T X AB AF AJ AN AR AV AZ BD BH BL BP BT BX CB CF CJ '--'--
'--
05-02-13
recorded?
• Inspect the AT connector connection.
4 INSPECT TFT SENSOR Yes Go to the next step.
• Inspect the TFT sensor. No Replace the TFT sensor, then go to Step 8.
(See 05-13-26 TRANSMISSION FLUID
TEMPERATURE (TFT) SENSOR
INSPECTION [5R55S])
• Is the digital TR sensor normal?
6 INSPECT TFT SENSOR CIRCUIT FOR SHORT Yes Repair or replace the wiring harness, then go to Step 8.
TO GROUND No Go to the next step.
• Inspect for continuity between the AT terminals
(wiring harness-side) and body ground.
- K and body ground
- L and body ground
7 INSPECT TFT SENSOR CIRCUIT FOR OPEN Yes Go to the next step.
CIRCUIT No Repair or replace the wiring harness, then go to Step 8.
• Inspect the following AT terminals (wiring
harness-side) and TCM terminals (wiring
harness-side):
-KandAY
-Land BH
P0712 OR P0713 COMPLETED (See 05-13-44 TCM REMOVAUINSTALLATION [5R55S].)
connectors.
PDS.
[5R55S].)
• Are DTCs except for P0711, P0712 and P0713 (See 05-02-5 DTC TABLE [5R55S].)
output? No DTC troubleshooting completed.
05-02-14
DTC P0715, P0717, P0718 [5R55S]
id0502c1806200
DTC P0715 Turbine shaft speed (TSS) sensor malfunction

DTC P0717 Turbine shaft speed (TSS) sensor signal is not input.
DTC P0718 Turbine shaft speed (TSS) sensor signal noise
• P0715: TCM detects insufficient TSS sensor signal while driving
DETECTION
• P0717: TCM detects that TSS sensor is not input while driving
CONDITION
• P0718: TCM detects intermittent TSS sensor signal input while driving
• TSS sensor malfunction.
• Short to ground in wiring harness between TSS sensor terminal A (wiring harness-side) and TCM terminal
AP (wiring harness-side).
• Open circuit in wiring harness between TSS sensor terminal A (wiring harness-side) and TCM terminal AP
POSSIBLE
CAUSE
• Open circuit in wiring harness between TSS sensor terminal B (wiring harness-side) and TCM terminal AH
• Damaged connectors between TSS sensor and TeM.
TCM
TSS SENSOR WIRING TSS SENSOR

HARNESS-SIDE CONNECTOR @@

CONNECTOR
r---
A E I M Q U Y AC AG AK AO AS AW BA BE BI BM BQ BU BY CC CG -c--
B F J N R AD AH AL AP AT AX BB BF BJ BN BR BV BZ CD CH CK CN
~
V Z r--r--
CL CO
C G K 0 S W AA AE AI AM AQ AU AY BC BG BK BO BS BW CA CE CI r--r--
CM CP
D H L P T X AB AF AJ AN AR AV AZ BD BH BL BP BT BX CB CF CJ '--'--
05-02-15
recorded?
3 INSPECT TSS SENSOR CONNECTOR FOR Yes Go to the next step.
POOR CONNECTION No Repair or replace connector and/or terminal, then go to
• Disconnect the TSS sensor connector.
4 INSPECT TSS SENSOR CIRCUIT FOR SHORT Yes Repair or replace the wiring harness, then go to Step 8.
• Inspect for continuity between TSS sensor
connector A (wiring harness-side) and body
ground.
6 INSPECT TSS SENSOR CIRCUIT FOR OPEN Yes Go to the next step.
• Inspect the following TSS sensor terminals
(wiring harness-side) and TCM terminals
(wiring harness-side):
-AandAP
-B and AH
7 INSPECT TSS SENSOR Yes Go to the next step.
• Inspect the TSS sensor. No Replace the TSS sensor, then go to the next step.
(See 05-13-28 TURBINE SHAFT SPEED (See 05-13-29 TURBINE SHAFT SPEED (TSS) SENSOR
(TSS) SENSOR INSPECTION [5R55S]) REMOVAUINSTALLATION [5R55S].)
• Is TSS sensor normal?
connectors.
PDS.
[5R55S].)
• Are any DTCs p~esent?
9 VERIFY OTCS Yes Go to the applicable DTC inspection.
05-02-16
DTC P0720, P0721 , P0722 [5R55S]
id0502c1806300
DTC P0720 Output shaft speed (OSS) sensor malfunction

DTC P0721 Output shaft speed (OSS) sensor signal noise
DTC P0722 Output shaft speed (OSS) sensor signal is not input.
• P0720: TCM detects insufficient ass sensor signal while driving
DETECTION
• P0721: TCM detects intermittent ass sensor signal input while driving
CONDITION
• P0722: TCM detects that ass sensor is not input while driving
• ass sensor malfunction.
• Short to ground in wiring harness between ass sensor terminal A (wiring harness-side) and TCM terminal
AG (wiring harness-side).
• apen circuit in wiring harness between ass sensor terminal A (wiring harness-side) and TCM terminal AG
POSSIBLE
CAUSE
• apen circuit in wiring harness between ass sensor terminal B (wiring harness-side) and TCM terminal AD
• Damaged connectors between ass sensor and TCM.
TCM
OSS SENSOR WIRING OSS SENSOR @@

•
I~~I
L -_ _ _ _ _ _ _ _ ~@~6______~D
®

CONNECTOR
r--
A E I M 0 U Y AC AG AK AO AS AW BA BE BI BM BO BU BY CC CG , . . - -
It
CK CN
B F J N R V Z AD AH AL AP AT AX BB BF BJ BN BR BV BZ CD CH I-- -
CL CO
C G K 0 S W AA AE AI AM AO AU AY BC BG BK BO BS BW CA CE CI
0 H L P T X AB AF AJ AN AR AV AZ BD BH
5i CP
BL BP BT BX CB CF CJ ' - - ' - -
'--
05-02-17
recorded?
3 INSPECT OSS SENSOR CONNECTOR FOR Yes Go to the next step.
• Disconnect the ass sensor connector.
4 INSPECT OSS SENSOR CIRCUIT FOR SHORT Yes Repair or replace the wiring harness, then go to Step 9.
• Inspect for continuity between ass sensor
ground.
6 INSPECT OSS SENSOR CIRCUIT FOR OPEN Yes Go to the next step.
• Inspect the following ass sensor terminals
-AandAG
-B and AD
7 INSPECT OSS SENSOR Yes Go to the next step.
• Inspect the ass sensor. No Replace the ass sensor, then go to the next step.
(See 05-13-32 OUTPUT SHAFT SPEED (See 05-13-33 OUTPUT SHAFT SPEED (aSS) SENSOR
(aSS) SENSOR INSPECTION [5R55S]) REMOVAUINSTALLATION [5R55S].)
• Is ass sensor normal?
connectors.
PDS.
[5R55S].)
05-02-18
DTe P0731 , P0732, P0733, P0734, P0735 [5R55S]
id0502c1814700
DTC P0731
Gear 1 incorrect
DTC P0732
Gear 2 incorrect
DTC P0733
Gear 3 incorrect
DTC P0734
Gear 4 incorrect
DTC Gear 5 incorrect
P0735
• P0731: Does not shift to 1st gear while driving
DETECTION •
P0732: Does not shift to 2nd gear while driving
CONDITION • P0733: Does not shift to 3rd gear while driving
• P0734: Does not shift to 4th gear while driving
• P0735: Does not shift to 5th gear while driving
• Shift solenoid A malfunction
• Shift solenoid B malfunction
POSSIBLE • Shift solenoid C malfunction
CAUSE • Shift solenoid D malfunction
• Transmission internal malfunction
• TCM malfunction
VERIFY RELATED SERVICE INFORMATION Yes Perform repair or diagnosis according to the available
• Turn the engine switch to the LOCK position, (See 05-02-5 DTC TABLE [5R55S].)
then to the ON position. No Go to the next step.
• Verify the DTCs in the TCM memory.
• Are DTCs except for P0731 , P0732, P0733,
P0734 and P0735 output?
3 SHIFT SOLENOID OPERATION INSPECTION Yes Go to the next step.
• Drive in D range. No Replace the solenoid body component, then go to Step 5.
• Connect the IDS/PDS to the DLC-2 and select (See 05-13-35 SOLENOID BODY REMOVAU
the following PIDs. INSTALLATION [5R55S].)
-SSA
-SSB
-SSC
-SSD
• Using the IDS/PDS, verify the operation status
of shift solenoid A, B, C and D while driving.
- 1GR: SSA on, SSB off, SSC off, SSD on
- 2GR: SSA on, SSB off, SSC on, SSD on
- 3GR: SSA on, SSB on, SSC off, SSD on
- 4GR: SSA off, SSB off, SSC off, SSD on
- 5GR: SSA off, SSB off, SSC on, SSD on
• Is the shift solenoid operation normal?
4 INSPECT ROAD TEST Yes Go to the next step.
• Road-test the vehicle to verify the respective No Inspect the symptom troubleshooting, then go to the next
shift points. step.
(See 05-13-8 ROAD TEST [5R55S].) (See 05-03-5 SYMPTOM TROUBLESHOOTING ITEM
• Are the shift points normal? TABLE [5R55S].)
5 VERIFY TROUBLESHOOTING OF DTC P0731 , Yes Replace the TCM, then go to the next step.
P0732, P0733, P0734 OR P0735 COMPLETED (See 05-13-44 TCM REMOVAUINSTALLATION [5R55S].)
connectors.
• Clear the DTC using the IDS/PDS.
[5R55S].)
• Are DTCs except for P0731 , P0732, P0733, (See 05-02-5 DTC TABLE [5R55S].)
05-02-19
DTC P0740, P0741 , P0742, P0743, P0744 [SRSSS]

id0502c1814800
DTC P0740 Torque converter clutch (TCC) control solenoid circuit malfunction (open circuit)
DTC P0741 Torque converter clutch (TCC) control solenoid circuit malfunction (stuck off)
DTC P0742 Torque converter clutch (TCC) control solenoid circuit malfunction (stuck on)
DTC P0743 Torque converter clutch (TCC) control solenoid circuit malfunction (open or short circuit)
DTC P0744 Torque converter clutch (TCC) control solenoid circuit malfunction (short to power)
• PO?40: Open circuit in circuit between TCC control solenoid and TCM, or in TCC control solenoid internal
circuit.
• PO?41: Torque converter clutch slipping indicating a mechanical or hydraulic concern.
DETECTION •
PO?42: Short to ground in circuit between TCC control solenoid and TCM, or in TCC control solenoid
internal circuit.
CONDITION
• PO?43: Open or short circuit in circuit between TCC control solenoid and TCM, or in TCC control solenoid
internal circuit.
• PO?44: Short to power supply in circuit between TCC control solenoid and TCM, or in TCC control solenoid
internal circuit.
• TCC control solenoid malfunction.
• Short to ground in wiring harness between AT connector terminal H (wiring harness-side) and TCM
terminal A (wiring harness-side).
POSSIBLE • Short to power supply in wiring harness between AT connector terminal H (wiring harness-side) and TCM
terminal A (wiring harness-side).
CAUSE
• Open circuit in wiring harness between AT connector terminal I (wiring harness-side) and TCM terminal CK
• Open circuit in wiring harness between AT connector terminal H (wiring harness-side) and TCM terminal A
• Damaged connector between AT connector and TCM.

@ HARNESS-SIDE CONNECTOR
TCC CONTROL -=
® CV@ ® SOLENOID
C!S" "'-~
~IGIII~
® ~O~)ruJ
®
~IHIJI~
® CV@®
A"" //I"H'
~" "'r-'
I~~I
CONNECTOR
-
A E I M Q U Y AC AG AK AO AS W BA BE BI BM BQ BU BY CC CG ; - - ; - -
B F J N R V Z AD AH AL AP AT AX BB BF BJ BN BR BV BZ CD CK CN
CH I--
~
I--
CL CO
C G K 0 S W AA AE AI AM AQ AU AY BC BG BK BO BS BW CA CE CI I-- I--
CM CP
D H L P T X AB AF AJ AN AR AV AZ BD BH BL BP BT BX CB CF CJ ' - - ' - -
-
I~~I
recorded?
05-02-20
VERIFY RELATED SERVICE INFORMATION Yes Perform repair or diagnosis according to the available
• Verify related Service Information availability. • If the vehicle is not repaired, go to the next
• Is any related Service Information available?
3 INSPECT AT CONNECTOR FOR POOR
CONNECTION Repair or replace the connector and/or terminals, then go
4 INSPECT POWER SUPPLY CIRCUIT
(engine off).
• Inspect voltage at AT connector terminal I
5 INSPECT RESISTANCE
• Turn the engine switch to the LOCK position.
• Inspect resistance between AT terminal I and H
(transmission case side).
• Is resistance within 9-16 ohms?
(See 05-13-34 SOLENOID VALVE
INSPECTION [5R55S].)
6 INSPECT TCM CONNECTOR FOR POOR
CONNECTION
• Disconnect the TCM connector.
7 INSPECT TCC CONTROL SOLENOID CIRCUIT
FOR OPEN CIRCUIT No Repair or replace the wiring harness, then go to Step 10.
terminal (wiring harness-side) and the AT
connector terminal (wiring harness-side).
-CKand I
-Aand H
8 INSPECT TCC CONTROL SOLENOID CIRCUIT Yes Repair or replace the wiring harness, then go to the Step
FOR SHORT TO GROUND 10.
• Inspect for continuity between AT connector No Go to the next step.
terminal (wiring harness-side) and body
ground.
- I and body ground
- H and body ground
9 INSPECT TCC CONTROL SOLENOID CIRCUIT
FOR SHORT TO POWER SUPPLY Repair or replace the wiring harness, then go to the next
• Turn the engine switch to the ON position step.
(engine off).
• Inspect voltage at AT connector terminal H
connectors.
PDS.
[5R55S].)
• Are DTCs except for P0740, P0741 , P0742, (See 05-02-5 DTC TABLE [5R55S].)
P0743 and P0744 output?
05-02-21
DTCP0745,P0748,P0960,P0962,P0963[5R55S]
id0502c1815300
DTC P0745 Pressure control solenoid A malfunction (low pressure)

DTC P0748 Pressure control solenoid A circuit malfunction (not operation)
DTC P0960 Pressure control solenoid A circuit malfunction (open circuit)
DTC P0962 Pressure control solenoid A circuit malfunction (short to ground)
DTC P0963 Pressure control solenoid A circuit malfunction (short to power supply)
• P0745: Incorrect shift pattern indicating mechanical or hydraulic failure in the transmission.
• P0748: Possible slip in gear and/or 3GR ratio.
• P0960: Open circuit in circuit between pressure control solenoid 0 and TCM, or in pressure control
DETECTION solenoid A internal circuit.
CONDITION • P0962: Short to ground in circuit between pressure control solenoid A and TCM, or in pressure control
solenoid A internal circuit.
• P0963: Short to power supply in circuit between pressure control solenoid A and TCM, or in pressure
control solenoid A internal circuit.
• Pressure control solenoid A malfunction.
• Short to ground in wiring harness between AT connector terminal 0 (wiring harness-side) and TCM
terminal I (wiring harness-side).
POSSIBLE • Short to power supply in wiring harness between AT connector terminal 0 (wiring harness-side) and TCM
terminal I (wiring harness-side).
CAUSE
• Open circuit in wiring harness between AT connector terminal 0 (wiring harness-side) and TCM terminal I

® HARNESS-SIDE CONNECTOR
~®
PRESSURE CONTROL
@
cv®
L~
SOLENOID A
c;» "'\,,~
frF'IBIEIGIIIKIMI~'
® I[~ 0 r£r nltJ I
P'
~IHI*IOI<
® @
I""'"
cv®® //I'ey
'/" ""r:' ~
I~~I
CONNECTOR
-
A E I M Q U Y AC AG AK AO AS AW BA BE BI BM BQ BU BY CC CG , - - - -
CK CN
-
I~
B F J N R V Z AD AH AL AP AT AX BB BF BJ BN BR BV BZ CD CH r--
CL CO
C G K 0 S W AA AE AI AM AQ AU AY BC BG BK BO BS BW CA CE CI r-- -
CM CP
0 H L P T X AB AF AJ AN AR AV AZ BD BH BL BP BT BX CB CF CJ ' - - -
'--
I~~I
recorded?
05-02-22

4 INSPECT POWER SUPPLY CIRCUIT Yes Go to the next step.
• Turn the engine switch to the ON position No Go to Step 6.
(engine off).
5 INSPECT RESISTANCE Yes Go to the next step.
• Turn the engine switch to the LOCK position. No Replace the pressure control solenoid A, then go to Step
• Inspect resistance between AT terminal I and 0 10.
• Is resistance within 3.3-7.5 ohms?
• Disconnect the TCM connector. Step 10.
7 INSPECT PRESSURE CONTROL SOLENOID A Yes Go to the next step.
CIRCUIT FOR OPEN CIRCUIT No Repair or replace the wiring harness, then go to Step 10.
-CKand I
- I andO
8 INSPECT PRESSURE CONTROL SOLENOID A Yes Repair or replace the wiring harness, then go to the Step
CIRCUIT FOR SHORT TO GROUND 10.
• Inspect continuity between AT connector No Go to the next step.
ground.
- I and body ground
- 0 and body ground
9 INSPECT PRESSURE CONTROL SOLENOID A Yes Go to the next step.
CIRCUIT FOR SHORT TO POWER SUPPLY No Repair or replace the wiring harness, then go to the next
(engine off).
• Inspect voltage at AT connector terminal 0
P0748, P0960, P0962 OR P0963 COMPLETED (See 05-13-44TCM REMOVAUINSTALLATION [5R55S].)
connectors.
PDS.
[5R55S].)
05-02-23
DTC P0750, P0753 [5R55S]

id0502c1814900
DTC P0750 Shift solenoid A circuit malfunction (open or short circuit)

DTC P0753 Shift solenoid A circuit malfunction (open or short circuit)
• P0750: Open or short circuit in circuit between shift solenoid A and TCM, or in shift solenoid A internal
DETECTION circuit.
CONDITION • P0753: Open or short circuit in circuit between shift solenoid A and TCM, or in shift solenoid A internal
circuit.
• Shift solenoid A malfunction.
• Short to ground in wiring harness between AT connector terminal D (wiring harness-side) and TCM
terminal B (wiring harness-side).
POSSIBLE • Short to power supply in wiring harness between AT connector terminal D (wiring harness-side) and TCM
terminal B (wiring harness-side).
CAUSE
• Open circuit in wiring harness between AT connector terminal D (wiring harness-side) and TCM terminal B
t
C.)';';
CV@ ®
......,1,./
SHIFT SOLENOID A
L~
,
frrul BI EIGI I IKIMIl!: ~
® ~ 0 @J~
'~IDIFIHIJILlolr.:
® CV@® ®
///'.
B'"
'/" ...,,0,./ -
I~~I
CONNECTOR
-
A E I M Q U Y AC AG AK AO AS AW BA BE BI BM BQ BU BY CC CG - -
B F J N R Z AD AH AL AP AT AX BB BF BJ BN BR BV BZ CD CH -CK -CN
~
V
CL CO
C G K 0 S W AA AE AI AM AQ AU AY BC BG BK BO BS BW CA CE CI - -
CM CP
0 H L P T X AB AF AJ AN AR AV AZ BD BH BL BP BT BX CB CF CJ ' - - -
-
I~~I
RECORDED. No Record the FREEZE FRAME DATA on the repair order,
recorded?
05-02-24

(engine off).
• Inspect the voltage at AT connector terminal I
• Turn the engine switch to the LOCK position. No Replace the shift solenoid A, then go to Step 10.
• Inspect resistance between AT terminal I and D
7 INSPECT SHIFT SOLENOID A CIRCUIT FOR Yes Go to the next step.
OPEN CIRCUIT No Repair or replace the wiring harness, then go to Step 10.
-CKand I
- Band D
8 INSPECT SHIFT SOLENOID A CIRCUIT FOR Yes Repair or replace the wiring harness, then go to the Step
SHORT TO GROUND 10.
ground.
- I and body ground
- D and body ground
9 INSPECT SHIFT SOLENOID A CIRCUIT FOR Yes Go to the next step.
SHORT TO POWER SUPPLY No Repair or replace the wiring harness, then go to the next
(engine off).
• Inspect voltage at AT connector terminal D
connectors.
PDS.
[5R55S].)
05-02-25
DTe P0755, P0757, P0758 [5R55S]
id0502c1815000
DTC P0755 Shift solenoid B circuit malfunction (open or short circuit)

DTC P0757 Shift solenoid B malfunction (stuck on)
DTC P0758 Shift solenoid B circuit malfunction (open or short circuit)
• P0755: Open or short circuit in circuit between shift solenoid Band TCM, or in shift solenoid B internal
circuit.
DETECTION
CONDITION • P0757: Shift solenoid B mechanically stuck on,
• P0758: Open or short circuit in circuit between shift solenoid Band TCM, or in shift solenoid B internal
circuit.
• Shift solenoid B malfunction.
• Short to ground in wiring harness between AT connector terminal F (wiring harness-side) and TCM
terminal C (wiring harness-side).
POSSIBLE • Short to power supply in wiring harness between AT connector terminal F (wiring harness-side) and TCM
terminal C (wiring harness-side).
CAUSE
• Open circuit in wiring harness between AT connector terminal F (wiring harness-side) and TCM terminal C

~®
c;»
CV@ ®
",,1..1
SHIFT SOLENOID B
L
~IBIEIGIIIKIMll!:
r[~ 0 ~ DIJI
g
® /7
~IHIJI~
®
~:
CV@® ®
//1'
~" "",r:."
I~~I
CONNECTOR
-
A E I M Q U Y AC AG AK AO AS AW BA BE BI BM BQ BU BY CC CG r--r--
CK CN
~
B F J N R V Z AD AH AL AP AT AX BB BF BJ BN BR BV BZ CD CH r- r--
CL CO
C G K 0 S W AA AE AI AM AQ AU AY BC BG BK BO BS BW CA CE CI -CM r--
CP
0 H L P T X AB AF AJ AN AR AV AZ BD BH BL BP BT BX CB CF CJ -
-
.
I~~I
recorded?
05-02-26

(engine off).
• Turn the engine switch to the LOCK position. No Replace the shift solenoid B, then go to Step 10.
• Inspect resistance between AT terminal I and F
7 INSPECT SHIFT SOLENOID B CIRCUIT FOR Yes Go to the next step.
-CKand I
-C and F
8 INSPECT SHIFT SOLENOID B CIRCUIT FOR Yes Repair or replace the wiring harness, then go to the Step
SHORT TO GROUND 10.
• Inspect continuity between AT connector No Go to the next step.
ground.
- I and body ground
- F and body ground
9 INSPECT SHIFT SOLENOID B CIRCUIT FOR Yes Go to the next step.
(engine off).
• Inspect voltage at AT connector terminal F
connectors.
PDS.
[5R55S].)
• Are any DTCs pres ant?
05-02-27
DTC P0760, P0762, P0763 [SRSSS]
id0502c1815100
DTC P0760 Shift solenoid C circuit malfunction (open or short circuit)

DTC P0762 Shift solenoid C malfunction (stuck on)
DTC P0763 Shift solenoid C circuit malfunction (open or short circuit)
• P0760: Open or short circuit in circuit between shift solenoid C and TCM, or in shift solenoid C internal
circuit.
DETECTION
CONDITION • P0762: Shift solenoid C mechanically stuck on.
• P0763: Open or short circuit in circuit between shift solenoid C and TCM, or in shift solenoid C internal
circuit.
• Shift solenoid C malfunction.
• Short to ground in wiring harness between AT connector terminal B (wiring harness-side) and TCM
terminal F (wiring harness-side).
POSSIBLE • Short to power supply in wiring harness between AT connector terminal B (wiring harness-side) and TCM
terminal F (wiring harness-side).
CAUSE
• Open circuit in wiring harness between AT connector terminal B (wiring harness-side) and TCM terminal F
~®
C~»
CV@ ®
",\..1..1
SHIFT SOLENOID C
L~
,
f~IBIEIGIIIKIMI\!:~
® I ~ 0 ~ ~dbl
~IDIFIHIJILlolr.:
=-.:® CV@® ®
//("B
F..IN ,,\.!
I~~I
CONNECTOR
,--
A E I M Q U Y AC AG AK AO AS f,W BA BE BI BM BQ BU BY CC CG r--r--
CK CN
I~
B F J N R V Z AD AH AL AP AT AX BB BF BJ BN BR BV BZ CD CH r--r--
CL CO
C G K 0 S W AA AE AI AM AQ AU AY BC BG BK BO BS BW CA CE CI r-- f--
CM CP
0 H L P T X AB AF AJ AN AR AV AZ BD BH BL BP BT BX CB CF CJ '--'--
'---
L~~I
recorded?
2 VERIFY RELATED SERVICE INFORMATION Yes Perform repair or diagnosis according to the avail8.ble
05-02-28

(engine off).
• Turn the engine switch to the LOCK position. No Replace the shift solenoid C, then go to Step 10.
• Inspect the resistance between AT terminal I
and B (transmission case side).
7 INSPECT SHIFT SOLENOID C CIRCUIT FOR Yes Go to the next step.
-CKand I
- F and B
8 INSPECT SHIFT SOLENOID C CIRCUIT FOR Yes Repair or replace the wiring harness, then go to the Step
SHORT TO GROUND 10.
ground.
- I and body ground
- B and body ground
9 INSPECT SHIFT SOLENOID C CIRCUIT FOR Yes Go to the next step.
(engine off).
• Inspect the voltage at AT connector terminal B
connectors.
PDS.
[5R55S].)
05-02-29
DTe P076S, P0768 [SRSSS]
id0502c1815200
DTC P0765 Shift solenoid 0 circuit malfunction (open or short circuit)

DTC P0768 Shift solenoid 0 circuit malfunction (open or short circuit)
• P0765: Open or short circuit in circuit between shift solenoid D and TCM, or in shift solenoid D internal
DETECTION circuit.
CONDITION • P0768: Open or short circuit in circuit between shift solenoid D and TCM, or in shift solenoid D internal
circuit.
• Shift solenoid D malfunction.
• Short to ground in wiring harness between AT connector terminal E (wiring harness-side) and TCM
terminal D (wiring harness-side).
POSSIBLE • Short to power supply in wiring harness between AT connector terminal E (wiring harness-side) and TCM
terminal D (wiring harness-side).
CAUSE
• Open circuit in wiring harness between AT connector terminal E (wiring harness-side) and TCM terminal D

~®
C~»
cv® ®
",1./
SHIFT SOLENOID 0
£~
~::!JIBIEIGIIIKIMI\!;)'
® ~ 0 ~ ~[1tJ1
~ =:-.10 I F I HI J I LIolr. Ih
®
6''-'-
?'"
cv®® ®
//t'E'-
'" ":/
,/ ~
I~~I
CONNECTOR
-
B F J N R V Z AD AH AL AP AT AX BB BF BJ BN BR BV BZ CD CH -CK -CN
~ C
0
G
H
K
L
0 S W
P T X
AA
AB
AE AI AM
AF AJ AN
AQ AU AY BC
AR AV AZ BD
BG
BH
BK
BL
CL CO
BO BS BW CA CE CI - -
CM CP
BP BT BX CB CF CJ ' - - -
-
I~~I
recorded?
05-02-30

3 INSPECT AT CONNECTOR FOR POOR YesGo to the next step.
• Disconnect the AT connector. ,
(engine off).
• Turn the engine switch to the LOCK position. No Replace the shift solenoid D, then go to Step 10.
• Inspect resistance between AT terminal I and E
7 INSPECT SHIFT SOLENOID D CIRCUIT FOR Yes Go to the next step.
-CKand I
-D and E
8 INSPECT SHIFT SOLENOID D CIRCUIT FOR Yes Repair or replace the wiring harness, then go to the Step
SHORT TO GROUND 10.
ground.
- I and body ground
- E and body ground
9 INSPECT SHIFT SOLENOID D CIRCUIT FOR Yes Go to the next step.
SHORT TO POWER SUPPLY 'No Repair or replace the wiring harness, then go to the next
(engine off).
• Inspect the voltage at AT connector terminal E
connectors.
PDS.
[5R55S].)
05-02-31
DTCP0775,P0778,P0964,P0966,P0967[5R55S]
id0502c1815400
DTC P077S Pressure control solenoid B malfunction (low pressure)

DTC P0778 Pressure control solenoid B circuit malfunction (not operation)
DTC P0964 Pressure control solenoid B circuit malfunction (open circuit)
DTC P0966 Pressure control solenoid B circuit malfunction (short to ground)
DTC P0967 Pressure control solenoid B circuit malfunction (short to power supply)
• P0778: Incorrect gear ratio in 2GR and 5GR.
• P0964: Open circuit in circuit between pressure control solenoid Band TCM, or in pressure control
DETECTION solenoid B internal circuit.
CONDITION • P0966: Short to ground in circuit between pressure control solenoid Band TCM, or in pressure control
solenoid B internal circuit.
• P0967: Short to power supply in circuit between pressure control solenoid Band TCM, or in pressure
control solenoid B internal circuit.
• Pressure control solenoid B malfunction.
• Short to ground in wiring harness between AT connector terminal M (wiring harness-side) and TCM
terminal J (wiring harness-side).
POSSIBLE • Short to power supply in wiring harness between AT connector terminal M (wiring harness-side) and TCM
terminal J (wiring harness-side).
CAUSE
• Open circuit in wiring harness between AT connector terminal M (wiring harness-side) and TCM terminal J

~®
PRESSURE CONTROL
CV@ ® SOLENOID B
c~»
""~ L
frrIBIEIGIIIKIMll!:
g
® ~Oc£rJ P" []]I

~
,7/
:::-IDIFIHIJILlolr.
® CV@® ®
\,.., //I'M'
'!,.IN "\! 'Y
I~~I
CONNECTOR
;--
A E I M Q U Y AC AG AK AO AS AW BA BE BI BM BQ BU BY CC CG r - r -
CK CN
~
B F J N R V Z AD AH AL AP AT AX BB BF BJ BN BR BV BZ CD CH r- r--
CL CO
C
O H
G K
L
0
P
S
T
W AA AE AI AM AQ AU AY BC BG BK BO BS BW CA CE CI
X AB AF AJ AN AR AV AZ BD BH BL BP BT BX CB CF CJ
SA s;-
'--'--
'---
I~~I
recorded?
05-02-32

(engine off).
• Turn the engine switch to the LOCK position. No Replace the pressure control solenoid B, then go to Step
• Inspect resistance between AT terminal I and 10.
M (transmission case side).
7 INSPECT PRESSURE CONTROL SOLENOID B Yes Go to the next step.
-CKand I
- J and M
a INSPECT PRESSURE CONTROL SOLENOID B Yes Repair or replace the wiring harness, then go to the Step
ground.
- I and body ground
- M and body ground
9 INSPECT PRESSURE CONTROL SOLENOID B Yes Go to the next step.
(engine off).
• Inspect the voltage at AT connector terminal M
10 VERIFY TROUBLESHOOTING OF DTC P077S, Yes Replace the TCM, then go to the next step.
P077S, P0964, P0966 OR P0967 COMPLETED (See 05-13-44 TCM REMOVAUINSTALLATION [5R55S].)
connectors.
PDS.
[5R55S].)
• Are DTCs except for P0775, P077a, P0964, (See 05-02-5 DTC TABLE [5R55S].)
05-02-33
DTC P0791 , P0794 [5R55S]

id0502c1814100
DTC P0791 Intermediate shaft speed (ISS) sensor malfunction

DTC P0794 Intermediate shaft speed (ISS) sensor signal noise
DETECTION • P0791: TCM detects insufficient ISS sensor signal while driving
CONDITION • P0794: TCM detects intermittent ISS sensor signal input while driving
• ISS sensor malfunction.
• Short to ground in wiring harness between ISS sensor terminal A (wiring harness-side) and TCM terminal
AS (wiring harness-side).
• Open circuit in wiring harness between ISS sensor terminal A (wiring harness-side) and TCM terminal AS
POSSIBLE
CAUSE
• Open circuit in wiring harness between ISS sensor terminal B (wiring harness-side) and TCM terminal AM
• Damaged connectors between ISS sensor and TCM.
TCM
ISS SENSOR WIRING

ISS SENSOR
®
®®
~
«', S
•
A
(j)
B
®
® ® //Q
I~~I "'9

CONNECTOR
r--
A E I M Q U Y AC AG AK AO AS AW BA BE BI BM BQ BU BY CC CG r--r-
t
B F J N R V Z AD AH AL AP AT AX BB BF BJ BN BR BV BZ CD CK CN
CH r-r-
CL CO
C G K 0 S W AA AE AI AM AQ AU AY BC BG BK BO BS ~W CA CE CI
0 H L P T X AB AF AJ AN AR AV AZ BO BH BL BP BT BX CB CF CJ '~
--'---
I~~I
05-02-34
recorded?
3 INSPECT ISS SENSOR CONNECTOR FOR Yes Go to the next step.
• Disconnect the ISS sensor connector.
4 INSPECT ISS SENSOR CIRCUIT FOR SHORT Yes Repair or replace the wiring harness, then go to Step 8.
• Inspect for continuity between ISS sensor
ground.
6 INSPECT ISS SENSOR CIRCUIT FOR OPEN Yes Go to the next step.
• Inspect the following ISS sensor terminals
-AandAS
- B and AM
7 INSPECT ISS SENSOR Yes Go to the next step.
• Inspect the ISS sensor. No Replace the ISS sensor, then go to the next step.
(See 05-13-30 INTERMEDIATE SHAFT (See 05-13-31 INTERMEDIATE SHAFT SPEED (ISS)
SPEED (ISS) SENSOR INSPECTION SENSOR REMOVAUINSTALLATION [5R55S].)
[5R55S])
• Is ISS sensor normal?
connectors.
PDS.
[5R55S].)
05-02-35
DTCP079S,P0798,P0968,P0970,P0971 [SRSSS]
id0502c1815500
DTC P0795 Pressure control solenoid C malfunction (low pressure)

DTC P0798 Pressure control solenoid C circuit malfunction (not operation)
DTC P0968 Pressure control solenoid C circuit malfunction (open circuit)
DTC P0970 Pressure control solenoid C circuit malfunction (short to ground)
DTC P0971 Pressure control solenoid C circuit malfunction (short to power supply)
• P0798: Incorrect gear ratio in 4GR and 5GR.
• P0968: Open circuit in circuit between pressure control solenoid C and TCM, or in pressure control
DETECTION solenoid C internal circuit.
CONDITION • P0970: Short to ground in circuit between pressure control solenoid C and TCM, or in pressure control
solenoid C internal circuit.
• P0971: Short to power supply in circuit between pressure control solenoid C and TCM, or in pressure
control solenoid C internal circuit.
• Pressure control solenoid C malfunction.
• Short to ground in wiring harness between AT connector terminal G (wiring harness-side) and TCM
terminal M (wiring harness-side).
POSSIBLE • Short to power supply in wiring harness between AT connector terminal G (wiring harness-side) and TCM
terminal M (wiring harness-side).
CAUSE
• Open circuit in wiring harness between AT connector terminal G (wiring harness-side) and TCM terminal M

® HARNESS-SIDE CONNECTOR
~®
PRESSURE CONTROL
CV@ ® SOLENOID C
c)>> ",\.1..1 L
lruIBIEIGIIIKIMll!:
g
@
liE
~ 0 ~ D1J1
~ =-101 F I HI J I L I olr.:
F'"
®
M""
;:to
cv®® ®
//I'G""
",,;/
~7
I~~I
CONNECTOR
r--
A E I M 0 Y AC AG AK AO AS AW BA BE BI BM BO BU BY CC CG r - r -
U
CK CN
I~
B F J N R V
Z AD AH AL AP AT AX BB BF BJ BN BR BV BZ CD CH f-- f--
CL CO
C
O
G
H
K
L
0
P
S W AA AE AI AM AO AU AY BC BG BK BO BS BW CA CE CI
T X AB AF AJ AN AR AV AZ BO BH BL BP BT BX CB CF CJ
SA s;-
'--'--
'--
I~~I
recorded?
05-02-36

(engine off).
• Turn the engine switch to the LOCK position. No Replace the pressure control solenoid C, then go to Step
• Inspect resistance between AT terminal I and G 10.
7 INSPECT PRESSURE CONTROL SOLENOID C Yes Go to the next step.
-CKand I
-Mand G
8 INSPECT PRESSURE CONTROL SOLENOID C Yes Repair or replace the wiring harness, then go to the Step
• Inspect for co'ntinuity between AT connector No Go to the next step.
ground.
- I and body ground
- G and body ground
9 INSPECT PRESSURE CONTROL SOLENOID C Yes Go to the next step.
(engine off).
• Inspect the voltage at AT connector terminal G
connectors.
PDS.
[5R55S].)
05-02-37
DTC P1635 [5R55S]

id0502c1813800
DTC P1635 Tire/axle ratio out of acceptable range

DETECTION
• Tire size or axle ratio message from the PCM corrupt or invalid.
CONDITION
POSSIBLE • CAN malfunction

• TCM malfunction
2 VERIFY STORED DTe IN PCM AND ABS HUlCM Yes Go to the applicable DTC inspection.
• Turn the engine switch to the LOCK position, (See 04-02-2 ON-BOARD DIAGNOSIS [4W-ABS
then to the ON position. (EVEREST)].)
• Verify stored DTCs in PCM and ABS HU/CM. No Go to the next step.
• Are DTCs except for P1635 output?
4 ROAD TEST INSPECTION Yes Go to the next step.
• Road-test the vehicle to verify the respective No Inspect the symptom troubleshooting, then go to the next
shift points. step.
(See 05-13-8 ROAD TEST [5R55S].) (See 05-03-5 SYMPTOM TROUBLESHOOTING ITEM
• Are the shift points normal? TABLE [5R55S].)
COMPLETED (See 05-13-44 TCM REMOVAUINSTALLATION [5R55S].)
connectors.
• Clear the DTC using the IDS/PDS.
[5R55S].)
• Are DTCs except for P1635 output? (See 05-02-5 DTC TABLE [5R55S].)
DTC P1700 [5R55S]

id0502c1805000
DTC P1700 Transmission indeterminate malfunction

• Direct one-way clutch malfunction.
DETECTION Note
CONDITION • Engine rpm limited to 4,000 rpm. Failed a NEUTRAL condition in 1GR, 3GR or 4GR in automatic mode .
Only 2GR and 5GR available.
• Other DTCs that may set: P1700: P0745, P0750, P0755
• Direct one-way clutch malfunction
POSSIBLE • Shift solenoid B malfunction
CAUSE • Pressure control solenoid A malfunction
• Transmission internal malfunction
• TCM malfunction
05-02-38
• Turn the engine switch to the LOCK position, (See 05-02-5 OTC TABLE [5R55S].)
• Are OTCs except for P1700 output?
3 VERIFY DTC P1700 OUTPUT Yes Inspect the direct one-way clutch, then go to the next step.
• Drive in D range. No Go to the next step.
• Verify the OTC in the TCM memory.
• Are OTC P1700 output?
COMPLETED (See 05-13-44 TCM REMOVAUINSTALLATION [5R55Sj.)
connectors.
• Clear the OTC using the IDS/PDS.
[5R55Sj.)
• Are DTCs except for P1700 output? (See 05-02-5 OTC TABLE [5R55S].)
DTC P1711 [5R55S]

id0502c1814200
DTC P1711 ATF temperature out of on-board diagnostic range

DETECTION
CONDITION •
ATF temperature range too high or too low during on-board diagnostic.
POSSIBLE • TFT sensor malfunction.

CAUSE • TCM malfunction.
recorded?
• Turn the engine switch to the LOCK position, (See 05-02-5 OTC TABLE [5R55Sj.)
then to the ON position. No Warm or cool vehicle to normal operating temperature, then
• Verify the DTCs in the TCM memory. go to the next step.
• Are DTCs except for P1711 output?
COMPLETED (See 05-13-44 TCM REMOVAUINSTALLATION [5R55Sj.)
connectors.
PDS.
15R55Sj.)
• Are DTCs except for P1711 output? (See 05-02-5 OTC TABLE [5R55Sj.)
05-02-39
DTC P1780 [5R55S]

id0502c1807600
DTC P1780 OlD OFF switch circuit malfunction (open or short circuit)
DETECTION
CONDITION • Open or short circuit in circuit between OlD OFF switch and TCM, or in OlD OFF switch internal circuit
• OlD OFF switch malfunction.

• Short to ground in wiring harness between engine switch and OlD OFF switch terminal C (wiring harness-
side).
• Open circuit in wiring harness between engine switch and OlD OFF switch terminal C (wiring harness-
side).
POSSIBLE • Short to ground in wiring harness between OlD OFF switch terminal 0 (wiring harness-side) and TCM
terminal BM (wiring harness-side).
CAUSE
• Open circuit in wiring harness between OlD OFF switch terminal 0 (wiring harness-side) and TCM terminal
BM (wiring harness-side).
• Short to power supply in wiring harness between OlD OFF switch terminal 0 (wiring harness-side) and
TCM terminal BM (wiring harness-side).
• Damaged connector between OlD OFF switch and TCM.
SELECTOR LEVER
WIRING HARNESS-
SIDE CONNECTOR TCM
BE T@
IG1 ®
010 OFF SWITCH
~-0-@7, CD@® //,6

o B
® ® @'Y
I~~ I
TCM WIRING HARNESS-SIDE CONNECTOR
-
B F J N R V Z AD AH AL AP AT AX BB BF BJ BN BR BV BZ CD CH -CK -CN
~ C
D
G
H
K
L
0 S W
P T X
AA
AB
AE
AF
AI AM
AJ AN
AQ
AR
AU AY
AV AZ
BC
BD
BG
BH
BK
BL
BO BS BW CA
BP BT BX CB
CL CO
CE CI - -
CM CP
CF CJ - -
-
I~~I
recorded?
• Verify related'Service Information availability. • If the vehicle is not repaired, go to the next step.
• Is any related Service Infoqnation available? No Go to the next step.
3 INSPECT SELECTOR LEVER CONNECTOR Yes Go to the next step.
FOR POOR CONNECTION No Repair or replace the connector andlor terminals, then go
• Inspect the selector lever connector
connection.
• ~isconnect the selector lever connector.
• Inspect for poor connection (such as damagedl
• Is the connection normal? c
05-02-40
/

• Turn the engine switch to the ON position No Inspect the engine switch and wiring harness, then go to
(engine off). Step 10.
• Inspect the voltage at OlD OFF switch terminal
C (wiring harness-side).
• Is the voltage approx. 12 V? -
5 INSPECT 010 OFF SWITCH Yes Go to the next step.
• Turn the engine switch to the LOCK position. No Replace the selector lever, then go to Step 10.
• Inspect the OlD OFF switch. (See 05-14-4 SELECTOR LEVER REMOVAU
(See 05-13-19 OlD OFF SWITCH INSTALLATION.)
• Is the OlD OFF switch normal?
CONNECTION No Repair or replace connector andlor terminals, then go to
• ~isconnect the TCM connector. Step 10.
• Inspect for poor connection (such as damagedl
7 INSPECT 010 OFF SWITCH CIRCUIT FOR Yes Go to the next step.
terminal BM (wiring harness-side) and OlD
OFF switch terminal 0 (wiring harness-side).
8 INSPECT 010 OFF SWITCH CIRCUIT FOR Yes Repair or replace the wiring harness, then go to the Step
SHORT TO GROUND 10.
• Turn the engine switch to the LOCK position. No Go to the next step.
• Inspect for continuity between OlD OFF switch
. terminal 0 (wiring harness-side) and body
ground.
9 INSPECT 010 OFF SWITCH CIRCUIT FOR Yes Go to the next step.
(engine off).
• Inspect the voltage at OlD OFF switch terminal
o (wiring harness-side).
10 VERIFY TROUBLESHOOTING OFDTC P1780 Yes Re'):llace the TCM, then go to the next step.
connectors.
• Clear the OTC from memory using the 10SI
POS.
[5R55S].)
• Are any OTCs present?
11 VERIFY DTCS Yes Go to the applicable OTC inspection.
• Are OTCs except for P1780 output? (See 05-02-5 OTC TABLE [5R55S].)
05-02-41
DTC P1783 [5R55S]
id0502c1807700
DTC P1783 ATF overheating

DETECTION
• ATF temperature signal is 1270 C {270 OF} or more
CONDITION
• ATF level low
POSSIBLE • Deteriorated ATF
CAUSE • TFT sensor malfunction.
recorded?
3 VERIFYDTCS Yes Go to the applicable DTC inspection.
then to the ON position. No Go to SYMPTOM TROUBLESHOOTING, "NO.22
• Verify the DTCs in the TCM memory. TRANSMISSION OVERHEATS", then go to the next step.
• Are DTCs except for P1783 output? (See 05-03-24 NO.22 TRANSMISSION OVERHEATS
[5R55S].) I
4 INSPECT ATF CONDITION Yes Go to the next step.

• Inspect the ATF condition. No Replace the ATF, then go to Step 6.
(See 05-13-13 AUTOMATIC TRANSMISSION (See 05-13-13 AUTOMATIC TRANSMISSION FLUID (ATF)
FLUID (ATF) INSPECTION [5R55S].) INSPECTION [5R55S].) . .
• Is it normal?
5 NSPECT ATF LEVELVE Yes Go to the next step.
• Start the engine. No Add ATF to the specified level, then go to the next step.
• Warm up the AT. (See 05-13-16 AUTOMATIC TRANSMISSION FLUID (ATF)
• Is the ATF level within the specification? REPLACEMENT [5R55S].)
(See 05-13-13 AUTOMATIC TRANSMISSION
FLUID (ATF) INSPECTION [5R55S].)
connectors.
PDS.
[5R55S].)
7 VERIFYDTCS Yes Go to the applicable DTC inspection.
• Are DTCs except for P1783 output? (See 05-02-5 DTC TABLE [5R55S].)
05-02-42
OTC U0100, U0297 [5R55S]
id0502c1815600
DTC U0100 Communication error to PCM

DTC U0297 Communication error to PCM
DETECTION
• TCM cannot receive any signals from PCM.
CONDITION
• Short to ground in wiring harness between PCM terminal 195 (wiring harness-side) and TCM terminal CB
• Short to ground in wiring harness between PCM terminal 171 (wiring harness-side) and TCM terminal CF
• Short to power supply in wiring harness between PCM terminal 195 (wiring harness-side) and TCM
terminal CB (wiring harness-side).
• Short to power supply in wiring harness between PCM terminal 171 (wiring harness-side) and TCM
POSSIBLE
terminal CF (wiring harness-side).
CAUSE
• Open circuit in wiring harness between PCM terminal 195 (wiring harness-side) and TCM terminal CB
• Open circuit in wiring harness between PCM terminal 171 (wiring harness-side) and TCM terminal CF
• Damaged connector between PCM and TCM.
• PCM malfunction.
PCM TCM
TCM WIRING HARNESS-SIDE CONNECTOR
r--
A E I M 0 U Y AC AG AK AO AS AW BA BE BI BM BO BU BY CC CG --
B F J N R Z AD AH AL AP AT AX BB BF BJ BN BR BV BZ CD CH CK CN
~
V --
CLCO
C G K 0 S W AA AE AI AM AO AU AY BC BG BK BO BS BW CA CE CI - -
PMCP
0 H L P T X AB AF AJ AN AR AV AZ BD BH BL BP BT BX CB CF CJ '--'--
PCM WIRING HARNESS-SIDE CONNECTOR
124 123 22 21 ~20 19 18 117 16 115 14 113 112 111 110 109 108 107 106 105 104 102 102 101
148 147 46 45 144 43 42 141 40 139 38 137 136 135 134 133 132 131 130 128 128 121 126 125
172 171 n70 69 168 67 66 165 64 ~63 62 161 160 159 158 157 156 155 154 152 152 151 150 149
196 195 n94 93 192 91 90 189 88 n87 86 185 184 183 182 181 180 179 178 17 176 175 174 173
05-02-43
recorded?
3 INSPECT PCM FOR POOR CONNECTION Yes Go to the next step.
• Turn the engine switch to the LOCK position. No Repair or replace the connector and/or terminals, then go
• Inspect the PCM connection. to Step 8.
• Disconnect the PCM.
5 INSPECT CAN CIRCUIT FOR OPEN CIRCUIT Yes Go to the next step.
• Inspect for continuity between the TCM No Repair or replace the wiring harness, then go to Step 8.
terminal (wiring harness-side) and the PCM
terminal (wiring harness-side).
- CB and 195
-CF and 171
6 INSPECT CAN CIRCUIT FOR SHORT TO Yes Repair or replace the wiring harness, then go to the Step 8.
• Inspect for continuity between TCM terminal
(wiring harness-side) and body ground.
- CB and body ground
- CF and body ground
7 INSPECT CAN CIRCUIT FOR SHORT TO Yes Go to the next step.
POWER SUPPLY No Repair or replace the wiring harness, then go to the next
(engine off).
• Inspect the voltage at TCM terminal CB and CF
8 VERIFY TROUBLESHOOTING OF DTC U0100 Yes Replace the TCM, then go to the next step.
OR U0297 COMPLETED (See 05-13-44 TCM REMOVAUINSTALLATION [5R55S].)
connectors.
PDS.
[5R55S].)
• Are DTCs except for U01 00 and U0297 (See 05-02-5 DTC TABLE [5R55S].)
05-02-44
PID/DATA MONITOR INSPECTION [SRSSS]
id0502c1805600

items from the initial screen of the IDS/PDS .
4. Select "TCM".
2. Select "TCM".
absggw00000987
3. Select the PID from the PID table
4. Verify the PID data according to the directions on
the IDS/PDS screen.
Note
• Perform part inspection for the output device after TCM inspection .
• The PID/DATA MONITOR function monitors the calculated value of the input/output signals in the TCM.
Therefore, if a monitored value of an output device is out of specification, it is necessary to inspect the
monitored value of the input device related to the output device control. Since an output device
malfunction is not directly indicated as a malfunction of the monitored value for the output device, it is
necessary to inspect the output device individually using the simulation function.
PID/DATA MONITOR AND RECORD function table

UniU TCM
Monitor item Definition Condition/Specification
Condition terminal
BPP Brake switch on/off • Brake pedal depressed: on

N/A
• Other: off
Firm shaft control (FSC) • FSC not commanded by IDS/PDS PID output (off):
FIRM_ST 0/1 0 N/A
status requested
• FSC commanded by IDS/PDS PID output (on): 1
• 1GR: 1
Calculated gear range in • 2GR: 2
GEAR
TCM
1/2/3/4/5 • 3GR:3 N/A
• 4GR:4
• 5GR: 5
• 1GR: 1
PID used to command • 2GR:2
GEAR_OSC gear changes during 1/2/3/4/5 • 3GR: 3 N/A
Simulation Function • 4GR:4
• 5GR:5
ISS ISS sensor rpm Indicates intermediate shaft speed AM,AS
OSS OSS sensor rpm Indicates output shaft speed AD,AG
Pressure control solenoid Indicates pressure control solenoid A commanded
PCA pis I,CK
A pressure
Pressure control solenoid Indicates pressure control solenoid B commanded
PCB pis J, CK
B pressure
Pressure control solenoid Indicates pressure control solenoid C commanded
PCC pis M,CK
C pressure
RPM Engine speed rpm Indicates engine speed N/A
SSA Shift solenoid A on/off • Shift solenoid A operation: on B, CK

• Shift solenoid A not operation: off
SSB Shift solenoid B on/off • Shift solenoid B operation: on C,CK
• Shift solenoid B not operation: off
SSC Shift solenoid C on/off • Shift solenoid C operation: on F, CK
• Shift solenoid C not operation: off
SSD Shift solenoid D on/off • Shift solenoid D operation: on D,CK
• Shift solenoid D not operation: off
TCC TCC control solenoid % Indicates TCC control solenoid operation A,CK
Torque converter speed Indicates torque converter speed ratio (engine speed
TCCRAT ratio N/A
ratio compared with turbine shaft speed)
05-02-45
Unit! TCM
Monitor item Definition Condition/Specification
Condition terminal
TFT ATF temperature °C, of Indicates ATF temperature AY, BH
AX, BU, BY,
TR_D Digital TR sensor signal Indicates digital TR sensor signal
CA
Digital TR sensor signal AX, BU, BY,
TR_V V Indicates digital TR sensor signal voltage
voltage CA
TR1 TR1 switch 0/1 • TR1 switch open: 1

BY
• TR1 switch close: 0
TR2 TR2 switch 0/1 • TR2 switch open: 1 BU

TR3A TR3 switch 0/1 • TR3 switch open: 1 AX
TR4 TR4 switch 0/1 • TR4 switch open: 1 CA
TSS TSS sensor rpm Indicates turbine shaft speed AH,AP
VSS Vehicle speed mph Indicates vehicle speed AD,AG
Simulation Function Procedure

items from the initial screen of the IOS/POS.
4. Select "TCM".
• When using the POS (Pocket PC)
2. Select "TCM".
3. Select the simulation items from the PIO table. absggw00000987

• If there is no operation sound from the solenoid after the simulation function inspection is performed, it is
possible that there is an open or short circuit in the wiring harness, or solenoid, or sticking and operation
malfunction.
Simulation item table
Simulation item Applicable component Unit TCM terminal
PCA Pressure control solenoid A pis I, CK
SSA Shift solenoid A on/off B,CK
SSD Shift solenoid D on/off D, CK
TCC TCC control solenoid % A,CK
05-02-46
SYMPTOM TROUBLESHOOTING [5R55S]
05-03 SYMPTOM TROUBLESHOOTING [5R55S]

AUTOMATIC TRANSMISSION NO.14 ENGINE FLARES UP OR SLIPS
CONTROL SYSTEM WHEN UPSHIFTING OR DOWNSHIFTING
WIRING DIAGRAM [5R55S] ......•.. 05-03-2 [5R55S] •••.•.........•....•.••.•• 05-03-17
FOREWORD [5R55S] •.•.....••••... 05-03-3 NO.15 ENGINE FLARES UP OR SLIPS
BASIC INSPECTION [5R55S] ••....... 05-03-4 WHEN ACCELERATING VEHICLE
SYMPTOM TROUBLESHOOTING [5R55S] •.•.•...•.........••.••.•• 05-03-18
ITEM TABLE [5R55S] ...••...••.•.. 05-03-5 NO.16 JUDDER UPON TORQUE
QUICK DIAGNOSIS CHART CONVERTER CLUTCH (TCC)
[5R55S] ...••.••.•.•.•.•......... 05-03-7 OPERATION [5R55S] .......••.•..•. 05-03-18
NO.1 VEHICLE DOES NOT NO.17 EXCESSIVE SHIFT SHOCK
MOVE IN D RANGE, FROM N TO D OR N TO R
OR IN R POSITION [5R55S] .......•• 05-03-9 POSITION/RANGE [5R55S] ..••.•.... 05-03-19
NO.2 VEHICLE MOVES NO.18 EXCESSIVE SHIFT SHOCK IS FELT
IN N POSITION [5R55S] .••••....... 05-03-10 WHEN UPSHIFTING AND DOWNSHIFTING
NO.3 VEHICLE MOVES IN P POSITION, [5R55S] •••.•.•...•...•...•••••.•. 05-03-20
OR PARKING GEAR DOES NOT NO.19 EXCESSIVE SHIFT SHOCK ON
DISENGAGE WHEN P IS DISENGAGED TORQUE CONVERTER CLUTCH (TCC)
[5R55S] .••.•..•.•......••......• 05-03-10 [5R55S] •••.•.•.•••.•.•.... : ..•..• 05-03-21
NO.4 EXCESSIVE CREEP [5R55S] ..•. 05-03-11 NO.20 NOISENIBRATION FORWARD
NO.5 NO CREEP AT ALL [5R55S] •.... 05-03-11 OR REVERSE [5R55S] ....•........ 05-03-22
NO.6 LOW MAXIMUM SPEED AND NO.21 NO ENGINE BRAKING IN
POOR ACCELERATION [5R55S] ••••. 05-03-12 1GR POSITION OF MANUAL 1 RANGE
NO.7 NO SHIFTING [5R55S] ..••.••.. 05-03-13 [5R55S] .•.•.•.....•.•..••........ 05-03-23
NO.8 NO 2ND AND 5TH GEARS NO.22 TRANSMISSION OVERHEATS
(MANUAL 2ND IS OK) [5R55S] ...... 05-03-14 [5R55S] ....••..•......•....•.•... 05-03-24
NO.9 ABNORMAL SHIFTING NO.23 ENGINE STALLS WHEN
[5R55S] ...••..•••....•••.......• 05-03-14 SHIFTED TO D RANGE, OR IN R POSITION
NO.10 FREQUENT SHIFTING [5R55S] ....•...•...........•.•... 05-03-25
[5R55S] .•.......••.......•••••.. 05-03-15 NO.24 ENGINE STALLS WHEN DRIVING
NO.11 SHIFT POINT IS HIGH OR LOW AT SLOW SPEEDS OR STOPPING
[5R55S] •..........•.•.•..•.••.•. 05-03-15 [5R55S] ....•..........•.•........ 05-03-25
NO.12 TORQUE CONVERTER CLUTCH NO.25 STARTER DOES NOT WORK
(TCC) NON-OPERATION [5R55S] •... 05-03-16 [5R55S] •••••.•..••...••..•.•••.•• 05-03-25
NO.13 NO KICKDOWN [5R55S] ..••... 05-03-17
05-03-1
SYMPTOM TROUBLESHOOTING [SRSSS]
AUTOMATIC TRANSMISSION CONTROL SYSTEM WIRING DIAGRAM [SRSSS]
id0503c1809500
IG1 B+ B+
TCM
AT RELAY
OTHER
MODULE
SHIFT SOLENOID A
SHIFT SOLENOID B
4x4 4x4 HI
CONTROL SHIFT SOLENOID C
MODULE
4x4 LO
SHIFT SOLENOID D
IG1

J j-----'O
MI-----IO
INSTRUMENT
CLUSTER
TR1
TR2
TR4
OSSSENSOR
ISS SENSOR
TSS SENSOR
arnffw00001943
05-03-2
FOREWORD [5R55S]
idOS03c1800200
• When the customer reports a vehicle malfunction, inspect the malfunction indicator lamp (MIL) indication, OlD
OFF indicator light flash, and diagnostic trouble code (DTC), then diagnose the malfunction according to the
following flowchart.
If a DTC exists, diagnose the applicable DTC inspection. (See 05-02-5 DTC TABLE [5R55S].)
If a DTC does not exist, the MIL does not illuminate and OlD OFF indicator light flash, diagnose the
applicable symptom troubleshooting. (See 05-03-5 SYMPTOM TROUBLESHOOTING ITEM TABLE
[5R55S].)
CUSTOMER ARRIVES
WARNING LIGHT- NO WARNING LIGHT-

CHECK FOR • CHECK DTC

PRIORITIZED DTC • IGNITION ON TEST, IDLING
TEST
DTC
WITHOUTDTC
DIAGNOSE BY DTC
(ON-BOARD DIAGNOSTIC) DIAGNOSE BY SYMPTOM
• DTCTABLE (SYMPTOM TROUBLESHOOTING)
• DTC 1. DIAGNOSTIC INDEX
TROUBLESHOOTING 2. QUICK DIAGNOSIS CHART
FLOW 3. SYMPTOM
TROUBLESHOOTING
*: Malfunction Indicator Lamp (MIL), OlD OFF indicator light.
05-03-3
BASIC INSPECTION [SRSSS]
id0503c1800300

1 Perform the mechanical system test. Yes Go to the next step.
(See 05-13-4 MECHANICAL SYSTEM TEST No Repair or replace any malfunctioning parts according to the
[5R55S].) inspection result.
Is the mechanical system normal?
2 Turn the engine switch to the ON position. Yes Go to the next step.
When the selector lever is moved, does the No Inspect the selector lever and digital TR sensor. Repair or
selector illumination indicate a synchronized replace malfunctioning areas.
position to the lever location? Also, when other If the selector lever and digital TR sensor are normal, go to
ranges are selected from N or P during idling, the next step.
does the vehicle move within 1-2 5?
3 Inspect the ATF color, condition and level. Yes Go to the next step.
(See 05-13-13 AUTOMATIC TRANSMISSION No Repair or replace any malfunctioning parts according to the
FLUID (ATF) INSPECTION [5R55S].) inspection result.
Are the ATF color, odor and level normal? Flush the AT and cooler line if necessary.
4 Perform the line pressure test. Yes Go to the next step.
(See 05-13-4 MECHANICAL SYSTEM TEST No Adjust the accelerator cable if necessary.
[5R55S].) Repair or replace any malfunctioning parts according to the
Is the line pressure normal? inspection result.
(See 05-13-4 MECHANICAL SYSTEM TEST No Repair or replace any normal parts according to the
[5R55S].) inspection result.
Is the stall speed normal?
6 Inspect the value at the following PCM and TCM Yes Perform the symptom troubleshooting and the follow
PIDs using the IDS/PDS. procedures.
(See 05-02-45 PID/DATA MONITOR No Repair or replace any malfunctioning parts according to the
INSPECTION [5R55S].) inspection result.
PCM PIDs:
• APP1
• APP2
• ECT
• RPM
• VPWR
TCM PIDs:
• TFT
• TR_D
• TR_V
• TSS
• ISS
• OSS
Is the PID value normal?
05-03-4
SYMPTOM TROUBLESHOOTING ITEM TABLE [SRSSS]
id0503c1800400
• Use the chart below to verify the trouble symptoms to diagnose the appropriate area.
1 Vehicle does not move in D range, or Vehicle does not move when AP is (See 05-03-9 NO.1 VEHICLE
in R position depressed. DOES NOT MOVE IN D
RANGE, OR IN R POSITION
[5R55S].)
2 Vehicle moves in N position Vehicle creeps in N position. (See 05-03-10 NO.2 VEHICLE
Vehicle creeps if brake pedal is not MOVES IN N POSITION
depressed in N position. [5R55S].)
3 Vehicle moves in P position, or parking Vehicle rolls when on a downward slope and (See 05-03-10 NO.3 VEHICLE
gear does not disengage when P tires do not lock in P position. MOVES IN P POSITION, OR
position is disengaged Tires locked when P position is disengaged, PARKING GEAR DOES NOT
vehicle does not move in D range, and R DISENGAGE WHEN P IS
position when AP is depressed, and engine DISENGAGED [5R55Sj.)
remains in stall condition.
4 Excessive creep Vehicle accelerates in D range, and R (See 05-03-11 NO.4
position without depressing accelerator EXCESSIVE CREEP [5R55Sj.)
pedal.
5 No creep at all Vehicle does not move in D range, or R (See 05-03-11 NO.5 NO
position when idling on flat, paved road. CREEP AT ALL [5R55Sj.)
6 Low maximum speed and poor Vehicle acceleration poor at start. (See 05-03-12 NO.6 LOW
acceleration Delayed acceleration when accelerator MAXIMUM SPEED AND
pedal depressed while driving. POOR ACCELERATION
[5R55S].)
7 No shifting Single shift range only. (See 05-03-13 NO.7 NO
Sometimes shifts correctly. SHIFTING [5R55Sj.)
8 No 2nd and 5th gears (Manual 2nd is Vehicle dose not shift to 2nd or 5th gear. (See 05-03-14 NO.8 NO 2ND
OK) AND 5TH GEARS (MANUAL
2ND IS OK) [5R55Sj.)
9 Abnormal shifting Shifts incorrectly (incorrect shift pattern). (See 05-03-14 NO.9
ABNORMAL SHIFTING
[5R55Sj.)
10 Frequent shifting Downshifting occurs immediately even when (See 05-03-15 NO.10
the accelerator pedal is depressed slightly in FREQUENT SHIFTING
D range. [5R55S].)
11 Shifts point is high or low Shift point is considerably different from (See 05-03-15 NO.11 SH IFT
automatic shift diagram. POINT IS HIGH OR LOW
Shift delays when accelerating. [5R55S].)
Shift occurs quickly when accelerating and
engine speed does not increase.
12 Torque converter clutch (TCC) non- TCC does not operate when vehicle reaches (See 05-03-16 NO.12
operation TCC operation range. TORQUE CONVERTER
CLUTCH (TCC) NON-
OPERATION [5R55Sj.)
13 No kickdown Does not downshift when accelerator pedal (See 05-03-17 NO.13 NO
is fully depressed within kickdown range. KICKDOWN [5R55Sj.)
14 Engine flares up or slips when When accelerator pedal is depressed, (See 05-03-17 NO.14 ENGINE
upshifting or downshifting engine speed increases but vehicle speed FLARES UP OR SLIPS WHEN
increases slowly. UPSHIFTING OR
When accelerator pedal is depressed while DOWNSHIFTING [5R55Sj.)
driving, engine speed increases but vehicle
speed does not.
15 Engine flares up or slips when Engine flares up when accelerator pedal is (See 05-03-18 NO.15 ENGINE
accelerating vehicle depressed for upshifting. FLARES UP OR SLIPS WHEN
Engine flares up suddenly when accelerator ACCELERATING VEHICLE
pedal is depressed for downshifting. [5R55Sj.)
16 Judder upon torque converter clutch Vehicle jolts when TCC is engaged. (See 05-03-18 NO.16
(TCC) operation JUDDER UPON TORQUE
CONVERTER CLUTCH (TCC)
OPERATION [5R55Sj.)
17 Excessive shift shock from N to D or N Strong shock is felt when shifting from N to (See 05-03-19 NO.17
to R position/range D or N to R position/range at idle. EXCESSIVE SHIFT SHOCK
FROM N TO D OR N TO R
POSITION/RANGE [5R55S].)
05-03-5

18 Excessive shift shock is felt when Excessive shift shock is felt when (See 05-03-20 NO.18
upshifting and downshifting depressing accelerator pedal to accelerate EXCESSIVE SHIFT SHOCK IS
at upshifting. FELT WHEN UPSHIFTING
During cruising, excessive shift shock is felt AND DOWNSHIFTING
when depressing accelerator pedal at [5R55S].)
downshifting.
19 Excessive shift shock on torque Strong shock is felt when TCC is engaged. (See 05-03-21 NO.19
converter clutch (TCC) EXCESSIVE SHIFT SHOCK
ON TORQUE CONVERTER
CLUTCH (TCC) [5R55S].)
20 Noise/vibration forward or reverse Transmission noisy in all positions and (See 05-03-22 NO.20 NOISE/
ranges. VIBRATION FORWARD OR
REVERSE [5R55S].)
21 No engine braking in 1GR position of Engine speed drops to idle but vehicle (See 05-03-23 NO.21 NO
manual 1 range coasts when accelerator pedal is released ENGINE BRAKING IN 1GR
when in 1GR position of manual 1 range at POSITION OF MANUAL 1
low vehicle speed. RANGE [5R55S].)
22 Transmission overheats Burnt smell emitted from transmission. (See 05-03-24 NO.22
Smoke is emitted from transmission. TRANSMISSION OVERHEATS
[5R55S].)
23 Engine stalls when shifted to D range, Engine stalls when shifting from N or P (See 05-03-25 NO.23 ENGINE
or in R position position to D range or R position at idle. STALLS WHEN SHIFTED TO
D RANGE, OR IN R POSITION
[5R55S].)
24 Engine stalls when driving at slow Engine stalls when brake pedal is (See 05-03-25 NO.24 ENGINE
speeds or stopping depressed while driving at low speed or STALLS WHEN DRIVING AT
stopping. SLOW SPEEDS OR
STOPPING [5R55S].)
25 Starter does not work Starter does not work even when P or N (See 05-03-25 NO.25
position is selected. STARTER DOES NOT WORK
[5R55S].)
05-03-6
QUICK DIAGNOSIS CHART [5R55S]
id0503c1800500
X: Applied
1 Vehicle does not move in D range, or in R position X X X
2 Vehicle moves in N position X
3 Vehicle moves in P position, or parking gear does not
disengage when P is disengaged X
4 Excessive creep X X X
5 No creep at all X X X X X X X X X
6 Low maximum speed and poor acceleration X X X X X X X X X X X X
7 No shifting X X X X X X X
8 No 2nd and 5th gears (Manual 2nd is OK) X X X X X X X X X X X X X X
9 Abnormal shifting X X X X X X X X X X X
10 Frequent shifting X X X X X X X X X
11 Shifts point is high or low X X X X X X X X X X X
12 Torque converter clutch (Tee) non-operation X X X X X X X X X X
13 No kickdown X X
14 Engine flares up or slips when upshifting or X X X X X X
downshifting X X
15 Engine flares up or slip when accelerating vehicle X X X X X X X X X X X X
16 Judder upon torque converter clutch (Tee) operation X X X
17 Excessive shift shock from N to D or N to R X X X X X X X X X
position/range
18 Excessive shift shock is felt when upshifting and
downshifting X X X X X X X X X
19 Excessive shift shock on torque converter X X X X X X X
clutch (TeC)
20 Noise/vibration forward or reverse
21 No engine braking in 1GR position of manual 1 range X X X X X X X
22 Transmission overheats X X
23 Engine stalls when shifted to D range, or in R position X X X X
24 Engine stalls when driving at slow speeds or stopping X
25 Starter does not work X X
Symptom item Electrical system components
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arnffw00001948
05-03-7·
X: Applied
1 Vehicle does not move in D range, or in R position X X X X X X X X X
2 Vehicle moves in N position X X
3 Vehicle moves in P position, or parking gear does not
disengage when P is disengaged
4 Excessive creep
5 No creep at all X X X X X X X X X X X
6 Low maximum speed and poor acceleration X X X X X X X X X X X X X X
7 No shifting X X X X X X X X X
8 No 2nd and 5th gears (Manual 2nd is OK) X X X X X X X X X
9 Abnormal shifting X X X X X X X X X X X X
10 Frequent shifting X X X
11 Shifts point is high or low X X X X
12 Torque converter clutch (Tee) non-operation X X X X X X X
13 No kickdown X X X X X X X X
14 Engine flares up or slips when upshifting or downshifting X X X X X X X X
15 Engine flares up or slip when accelerating vehicle X X X X X X X X X
16 Judder upon torque converter clutch (TeC) operation X X X X X X
17 Excessive shift shock from N to D or N to R position/range X X X X X X X X X
18 Excessive shift shock is felt when upshifting and
downshifting X X X X X X X X X X X X X X X
19 Excessive shift shock on torque converter clutch (Tee) X X X X X X X
21 No engine braking in 1GR position of manual 1 range X X X X X X X X X
22 Transmission overheats X X X X X X X X
23 Engine stalls when shifted to D range, or in R position X X X
24 Engine stalls when driving at slow speeds or stopping X X X
25 Starter does not work
Electrical system components Hydraulic
Symptom item Powertrain
system
system
AT outer parts components
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arnffw00001949
05-03-8
NO.1 VEHICLE DOES NOT MOVE IN D RANGE, OR IN R POSITION [5R55S]
id0503c1800600
1 Vehicle does not move in D range, or in R position

DESCRIPTION • Vehicle does not move when AP is depressed .
• If the vehicle does not move in D range or R position, basically, the malfunction is in the AT. (Vehicle will
move even with a malfunction in the TCM.) Since a malfunction is in the sensor circuit or output circuit is
the cause of the malfunction in the AT, inspect the sensors, output circuit, and the related wiring
harnesses.
1. Clutch slipped, worn (D range-Forward clutch, R position-Direct clutch, Coast clutch, Reverse band)
• Fluid pump malfunction
• Pressure control solenoid B malfunction
POSSIBLE • Pressure control solenoid C malfunction
CAUSE • Body ground malfunction
• Control valve body malfunction
2. Selector lever malfunction
3. Parking mechanism not operating properly
4. Torque converter malfunction
Note
• Before the following the troubleshooting steps, make sure that the Automatic Transmission On-Board
Diagnostic and Automatic Transmission Basic Inspections are conducted.
(See 05-03-4 BASIC INSPECTION [5R55S].)
When the vehicle is stopped on a flat, level road Yes Go to the next step.
and the engine is off, does the vehicle move i-:N-:-o-I-:C::':h-e-c.,.-k-,th:-e-pa-r-:-k-:-in--'g'-m-e-c""'h-a-n.,.-is-m-.-----------j
when it is pushed? (In D range or N, R positions
and brake released)
2 Disconnect the TCM connector. Yes Go to the next step.
Is the resistance between TCM ground terminal No Repair the open ground circuit.
CO and body ground, and between TCM ground
terminal CL and body ground less than 5.0
ohms?
3 Inspect the pressure control solenoid Band C. Yes Clean and inspect main control, if parts are damaged
(See 05-13-34 SOLENOID VALVE replace main control.
INSPECTION [5R55S].) If the problem remains, overhaul the transmission and repair
Is it normal? or replace any malfunctioning parts.
No Repair or replace any malfunctioning parts.
- If the malfunction remains, inspect the related Service Information and perform repair or diagnosis.
• If the vehicle repaired, the troubleshooting is completed.
• If the vehicle the not repaired or additional diagnostic information is not available, replace the TCM.
05-03-9
NO.2 VEHICLE MOVES IN N POSITION [5R55S]
id0503c1800700
2 Vehicle moves in N position
DESCRIPTION • Vehicle creeps in N position.

• Vehicle creeps if brake pedal is not depressed in N position.
• If the vehicle moves in N position, basically, the malfunction is in the AT. Since a malfunction in the
sensor circuit or output circuit is the cause of the malfunction in the AT, inspect the sensors, output
circuit, and the related wiring harnesses.
1. Clutch is burned (Forward clutch)
2. Selector lever position disparity. Although the selector indicator shows N position, the hydraulic
circuit shows D range or R position.
POSSIBLE • Incorrect fluid level
CAUSE • Fluid pump malfunction
• Shift control cables
• Main control
• Case and clutches
Note
1 Does the vehicle creep when the selector lever is Yes Go to the next step.
moved slightly in the N position? No Adjust the selector lever.
(See 05-14-2 SELECTOR CABLE ADJUSTMENT.)
CO and body ground, and between TCM ground Reconnect the TCM.
ohms?
3 Inspect following items. Yes Clean and inspect main control, if parts are damaged
• Fluid level replace main control.
• Fluid pump operation If the problem remains, overhaul the transmission and repair
• Shift control cables or replace any malfunctioning parts.
• Main control No Repair or replace any malfunctioning parts.
• Case and clutches
Are they normal?
• If the vehicle repaired, the troubleshooting is completed .
• If the vehicle the not repaired or additional diagnostic information is not available, replace the TCM .
NO.3 VEHICLE MOVES IN P POSITION, OR PARKING GEAR DOES NOT DISENGAGE WHEN P IS
DISENGAGED [5R55S]
id0503c1800800
3 Vehicle moves in P position, or parking gear does not disengage when P is disengaged
• Vehicle rolls on a downward slope in P position.
DESCRIPTION • Tires are locked when P is disengaged. Vehicle does not move in D range, and R position when
accelerator pedal is depressed, and engine remains in stall condition.
1. Improper adjustment of selector lever
POSSIBLE 2. Transmission case damaged
CAUSE 3. Parking mechanism malfunction (May have effect on noise or shock from transmission)
4. If vehicle moves in N position, perform No.2 "VEHICLE MOVES IN N POSITION"
05-03-10
NO.4 EXCESSIVE CREEP [5R55S]
id0503c1800900
4 Excessive creep
DESCRIPTION • Vehicle accelerates in 0 range, and R position without depressing accelerator pedal.
POSSIBLE 1. Engine idle speed high (transmission system is not cause of problem)
CAUSE 2. Go to No.9 "FAST IDLE/RUNS ON"
NO.5 NO CREEP AT ALL [5R55S]

id0503c1801000
5 No creep at all
DESCRIPTION • Vehicle does not move in 0 range and R position when idling on fiat, paved road.
• Either transmission is stuck in 4GR or clutch slippage due to a stuck 3-4 clutch.
1. Clutch is burned
• Shift solenoid 0 malfunction
• Shift solenoid C malfunction
• Pressure control solenoid A malfunction
• Body ground malfunction
POSSIBLE 2. Transmission fixed in 4GR (Operation of fail-safe function)
CAUSE • Short or open circuit in wiring harness
• Electronic parts of output and input system have malfunction
3. No engine torque
• Low engine RPM
• Torque converter malfunction
Note
Does the vehicle creep in any range/position? Yes Go to the next step.
No Inspect or adjust the selector lever.
(See 05-14-2 SELECTOR LEVER INSPECTION.) (See 05-
14-2 SELECTOR CABLE ADJUSTMENT.)
2 Check the value at the following PCM PIDs using Yes Go to the next step.
the IDS/PDS. i--N-o-l--,R'-e-p-a""-ir-o-r-r-ep-l-ac-e--'-an-y-m-a""lfu-n-c-ti-o-ni-n-g-p-a-rt-s-.- - - - - - 1
• APP1
• APP2
• RPM
Are PID values normal?
ohms?
4 Inspect the pressure control solenoid A. Yes Clean and inspect main control, if parts are damaged
(See 05-13-34 SOLENOID VALVE replace main control.
05-03-11
NO.6 LOW MAXIMUM SPEED AND POOR ACCELERATION [SRSSS]
id0503c1801100
6 Low maximum speed and poor acceleration
DESCRIPTION • Vehicle acceleration is poor at start.

• Delayed acceleration when accelerator pedal is depressed while driving.
• If the clutch is stuck or does not stay in 4GR, the malfunction is in the engine control system.
1. Clutch slippage, burned
• Shift solenoid D malfunction
• Pressure control solenoid A, Band C malfunction
2. Signal malfunction
• OSS sensor malfunction
• Sensor ground malfunction
POSSIBLE • Accelerator pedal position sensor malfunction
CAUSE • TSS sensor malfunction
3. Transmission fixed in 4GR (Operation of fail-safe function)
• Short or open circuit in wiring
• Electronic parts of output and input system have malfunction
4. Insufficient starting torque (Suspected when in-gear condition, shift control and engine circuit are
normal)
• Torque converter have malfunction (Poor operation, stuck)
• TFT sensor malfunction (Short or open circuit)
5. Digital TR sensor adjustment incorrect
Note
1 Go to No.12 "LACK/LOSS OF POWER- Yes Go to the next step.
ACCELERATION/CRUISE". No Repair or replace any malfunctioning parts.
Is the CIS system normal?
2 Disconnect the AT connector. Yes Go to the next step.
Does the vehicle operate as follows? No Clean and inspect main control, if parts are damaged
replace main control.
D range: 4GR (fixed) If the problem remains, overhaul the transmission and repair
R position: Reverse or replace any malfunctioning parts.
3 Drive the vehicle in D range. Yes Go to the next step.
Does the vehicle start from stop in first gear? No Check the value at the following.
Check the value at the following TCM PIDs using (See 05-02-45 PID/DATA MONITOR INSPECTION
the IDS/PDS. [5R55S].)
• GR_CM PCM PIDs (using IDS/PDS):
• GEAR • APP1
• APP2
• VSS
TCM PIDs (using IDS/PDS):
• TSS
• ISS
• OSS
• TR_D
Repair or replace any malfunctioning parts.
05-03-12

4 Inspect the value at the following TCM PIDs Yes Inspect the shift solenoids for sticking.
using the IDS/PDS. • If the shift solenoids are normal, go to the next step.
• SSA No Check the value at the following.
• SSB PCM PIDs (using IDS/PDS):
• SSC • APP
• SSD TCM PIDs (using IDS/PDS):
Are the PID values normal?
• OSS
• ISS
• TSS
• TR_D
5 Is the line pressure normal? Yes Go to the next step.
[5R55S].) inspection results.
6 Perform the stall test. Yes Reverify symptoms of malfunctioning.
(See 05-13-4 MECHANICAL SYSTEM TEST No Overhaul the transmission and repair or replace any
[5R55S].) malfunctioning parts.
NO.7 NO SHIFTING [5R55S]

id0503c1801200
7 No shifting
• Single shift range only.
DESCRIPTION
• Sometimes it shifts correctly.
• When the gear position is fixed in 4GR due to the fail-safe operation, the malfunction is in the AT.
• Perform malfunction diagnosis according to No.6 "LOW MAXIMUM SPEED AND POOR
ACCELERATION".·
POSSIBLE
CAUSE
• Accelerator pedal position sensor malfunction
• IAT sensor malfunction
• VSS signal malfunction
3. Transmission fixed in 4GR (Operation in fail-safe function)
• Short or open circuit in wiring harness
• Disconnected shift solenoid connector
• Poor ground of shift solenoid
• Overdrive planetary malfunction
• Center support malfunction
• Direct clutch malfunction
• Overdrive servo/band malfunction
05-03-13
NO.8 NO 2ND AND 5TH GEARS (MANUAL 2ND IS OK) [5R55S]
id0503c1814500
8 No 2nd and 5th gears (Manual 2nd is OK)

DESCRIPTION • Vehicle dose not shift to 2nd or 5th gear.
• Pressure control solenoid C malfunction
• TCM malfunction
POSSIBLE • Main control malfunction
CAUSE
Note
•Before following the troubleshooting steps, make sure that the Automatic Transmission On-Board
Diagnostic and Automatic Transmission Basic Inspection are conducted.
1 Verify that Manual 2nd is present and functions Yes Go to the next step.
correctly. No Go to symptom troubleshooting NO.8 "ABNORMAL
Is manual 2nd operating correctly? SHIFTING".
2 Inspect the following solenoids. Yes Clean and inspect main control, if parts are damaged
• Pressure control solenoid B replace main control.
• Pressure control solenoid C If the problem remains, overhaul the transmission and repair
(See 05-13-34 SOLENOID VALVE or replace any malfunction parts.
INSPECTION [5R55S].) No Repair or replace any malfunction parts.
Are they normal?
NO.9 ABNORMAL SHIFTING [5R55S]

id0503c1801400
9 Abnormal shifting
DESCRIPTION • Shifts incorrectly (incorrect shift pattern).
• There is a malfunction in the signal circuit which controls shifting (accelerator pedal position sensor,
TSS sensor, OSS sensor), the control valve is stuck, the accumulator (forward or servo apply) is stuck,
or the clutch circuit is stuck.
• Fluid level low
• Shift solenoid D malfunction
POSSIBLE • Body ground malfunction
CAUSE 2. Signal malfunction
3. Digital TR sensor malfunction
• Selector lever adjustment incorrect
• Digital TR sensor adjustment incorrect
Note
•Before the following the troubleshooting steps, make sure that the Automatic Transmission On-Board
05-03-14
Is the resistance between TCM ground terminal No Repair the open ground circuit. Reconnect the TCM
CO and body ground, and between TCM ground connector.
ohms?
2 Check the value at the following. Yes Clean and inspect main control, if parts are damaged
(See 05-02-45 PID/DATA MONITOR replace main control.
PCM PIDs (using IDS/PDS): or replace any malfunctioning parts.
• APP No Repair or replace any malfunctioning parts.
• TSS
• OSS
• VSS
Are they normal?
NO.10 FREQUENT SHIFTING [SRSSS]

id0503c1801500
10 Frequent shifting
DESCRIPTION • Downshifting occurs immediately even when the accelerator pedal is depressed slightly in D range.
• The circuit which is the cause is basically the same as NO.9 "ABNORMAL SHIFTING". However, a
POSSIBLE malfunction of the input signal to the accelerator pedal is position sensor, OSS sensor (including the
CAUSE sensor ground, sensor harness and connector), or clutch slippage (clutch stuck, low pressure in line)
may also be the cause.
NO.11 SHIFT POINT IS HIGH OR LOW [SRSSS]
11 Shift point is high or low

• Shift point is considerably different from automatic shift diagram.
DESCRIPTION • Shift delays when accelerating.
• Shift occurs quickly when accelerating and engine speed does not increase.
• If the transmission does not shift abnormally, there is a malfunction of the input signal to the accelerator
pedal position sensor, TSS sensor, or OSS sensor (including sensor ground).
POSSIBLE • If the engine speed is high or low, regardless of normal shifting, inspect the tachometer.
CAUSE • Verify that the output signal of the accelerator pedal position sensor change linearly.
• Verify fluid level and conditions.
• Verify main control operation.
05-03-15
NO.12 TORQUE CONVERTER CLUTCH (TCC) NON-OPERATION [5R55S]
id0503c1801700
12 Torque converter clutch (TCC) non-operation

DESCRIPTION • TCC does not operate when vehicle reaches TCC operation range.
• Basically, the TCC does not operate when the fail-safe is operating. Verify the DTC first.
Caution
• If the TCC is stuck, inspect it. In addition, inspect the oil cooler for foreign particles which
may have mixed in with the ATF.
1. TCC is burned
(1) Input sensor system malfunction
• ECT sensor
• TFT sensor
• Sensor ground
(2) Output solenoid valve system malfunction (Sticking)
• TCC control solenoid malfunction
POSSIBLE
(3) Main control malfunction (Poor operation, stuck)
CAUSE
• TCC hydraulic pressure system
• Improper pressures
• Converter malfunction
2. Accelerator pedal position sensor malfunction (Not operating linearly)
3. Brake switch malfunction (Always ON)
4. TCM malfunction
Note
1 Check the value at the following. Yes Go to the next step.
(See 05-02-45 PID/DATA MONITOR No Repair or replace any malfunctioning parts.
PCM PIDs (using IDS/PDS):
• APP
• VSS
• TFT
Are they normal?
Is the resistance between TCM ground terminal No Repair the wiring harness.
ohms?
3 Measure the resistance between TCM terminal Yes Go to the next step.
A and AT connector terminal H, and between No Repair the TCC control solenoid circuit. Reconnect the TCM
TCM terminal CK and AT connector terminal F. connector.
Are the resistances less than 5.0 ohms?
4 Inspect the TCC control solenoid. Yes Replace TCM.
(See 05-13-34 SOLENOID VALVE No Replace TCC control solenoid.
Are the TCC control solenoids operating or replace any malfunctioning parts.
properly?
05-03-16
NO.13 NO KICKDOWN [5R55S]
id0503c1801800
13 No kickdown
DESCRIPTION • Does not downshift when accelerator pedal is fully depressed within kickdown range.
POSSIBLE • If the transmission does not downshift though shifting is normal, the malfunction is in accelerator pedal
CAUSE position sensor circuit (including sensor ground, sensor harness and connector).
NO.14 ENGINE FLARES UP OR SLIPS WHEN UPSHIFTING OR DOWNSHIFTING [5R55S]

id0503c1801900
14 Engine flares up or slips when upshifting or downshifting

• When accelerator pedal is depressed for driving, engine speed increases but vehicle speed increases
slowly.
DESCRIPTION
• When accelerator pedal is depressed while driving, engine speed increases but vehicle speed does
not.
• The clutch is slipping because it is stuck or it line pressure is low.
1. Clutch stuck, slippage (forward clutch, 3-4 clutch, 2-4 brake band, one-way clutch)
• Incorrect fluid level
POSSIBLE • OSS sensor malfunction
CAUSE • Sensor ground malfunction
3. Poor operation of mechanical pressure
Note
Is the shift point normal? Yes Go to the next step.
No Go to symptom troubleshooting NO.9 "ABNORMAL
SHIFTING".
theIDS/PDS. ~N70~~R~e-p-a~ir-o-r-re-p~la-c-e~a-n-y-m--a~lfu-n-c~ti-on~i-ng--p-a~rts-.----------~
• APP
• ACT
Is the resistance between TCM ground terminal No Repair the wiring harness. Reconnect the TCM connector.
ohms?
4 Inspect PCA, PCB and PCC PIDs value. Yes Clean and inspect main control, if parts are damaged
Are the PCA, PCB and PCC PID values normal? or replace any malfunctioning parts.
~~~~~----~----~~~~~----------------~
05-03-17
NO.15 ENGINE FLARES UP OR SLIPS WHEN ACCELERATING VEHICLE [5R55S]
id0503c1802000
15 Engine flares up or slips when accelerating vehicle
DESCRIPTION • Engine flares up when accelerator pedal is depressed for upshifting.

• Engine flares up suddenly when accelerator pedal is depressed for downshifting.
POSSIBLE • The malfunction is basically the same as for No.14 "ENGINE FLARES UP OR SLIPS WHEN
UPSHIFTING OR DOWNSHIFTING". If conditions for No.14 worsen, the malfunction will develop to
CAUSE
No.15.
NO.16 JUDDER UPON TORQUE CONVERTER CLUTCH (TCC) OPERATION [5R55S]

id0503c1802100
16 Judder upon torque converter clutch (TCC) operation

DESCRIPTION • Vehicle jolts when TCC is engaged.
• Poor TCC engagement due to either slippage because the TCC is stuck or the line pressure is low
Caution
• If the TCC is stuck, inspect it. In addition, inspect the oil cooler for foreign particles which
may have mixed in with the ATF.
1. Torque converter clutch piston slipped, burned

• Line pressure high
• TCC control solenoid malfunction
POSSIBLE • Control valve body malfunction
Note
1 Disconnect TCM. Yes Go to the next step.
ohms?
2 Measure the resistance between the following Yes Go to the next step.
TCM and AT connector terminals. No Repair the TCC control solenoid circuit.
• TCM terminal A and AT connector terminal F
• TCM terminal CK and AT connector terminal
H
Is the resistance less than 5.0 ohms?
3 Inspect the TCC control solenoid. Yes Go to the next step.
(See 05-13-34 SOLENOID VALVE No Replace TCC control solenoid.
Is the solenoid valve operating properly? or replace any malfunctioning parts.
4 Inspect the PCA, PCB and PCC PID values. Yes Clean and inspect main control, if parts are damaged
No Replace the TCM.
- If the malfunction remains, inspect the related Service InforlT'ation and perform repair or diagnosis.
05-03-18
NO.17 EXCESSIVE SHIFT SHOCK FROM N TO D OR N TO R POSITION/RANGE [5R55S]
id0503c1802200
17 Excessive shift shock from N to D or N to R position/range

DESCRIPTION • Strong shock felt when shifting from N to 0 or N to R position/range.
• Shift shock may worsen when the fail-safe is operating. If no DTC is output, the shift shock may worsen
due to poor operation of the control valve body or sticking of the clutch.
1. Clutch burned (N~D: Forward clutch, N~R: Reverse servo or Direct clutch)
• Line pressure low, high
• TFT sensor malfunction
• Pressure control solenoid A malfunction (N~D only)
• Pressure control solenoid C malfunction (N~R only)
• Main control malfunction
POSSIBLE • Sensor ground malfunction
• Digital TR sensor misadjustment or malfunction
2. Poor hydraulic operation (Malfunction in range change)
• Forward clutch malfunction
• Reverse servo malfunction
3. Idle speed high
4. Poor tightening torque of engine mount, exhaust mount
Note
Does the shift shock occur only when the engine Yes Go to the next step.
is cold? i-:-:--I--:=-0---'--to-S=-t:-e-p--=3:-.- - - ' - - - - - - - - - - - - - - - - 1
N0 G
2 Disconnect the TCM connector. Yes Check the value at the following.
Is the resistance between the TCM ground (See 05-02-45 PID/DATA MONITOR INSPECTION
terminal CO and body ground, and between [5R55S].)
TCM ground terminal CL and body ground less PCM PIDs (using IDS/PDS):
than 5.0 ohms? • APP
• TFT
Repair or replace any malfunctioning parts.
No Repair the wiring harness. Reconnect the TCM connector.
3 Is the pressure normal? _ Yes Go to the next step.
(See 05-13-4 MECHANICAL SYSTEM TEST No Go to Step 5.
[5R55S].)
Is stall speed normal?
5 Inspect the voltage at the following TCM PID Yes Clean and inspect main control, if parts are damaged
using the IDS/PDS. replace main control.
(See05-02-45 PID/DATA MONITOR If the problem remains, overhaul the transmission and repair
INSPECTION [5R55S].) or replace any malfunctioning parts.
• TR_D No Repair or replace any malfunctioning parts.
Is the PID value normal?
theIDS/PDS. I-:N-:-o-'I--:R=-e-p-a-:-ir-o-r-re-p--:l-ac-e--'-an-y-m-a~lfu-n-c--:ti-O--:ni:-n-g-p-a-rt-s.-------I
• APP
ohms?
05-03-19

8 Inspect the PCA and PCC PID values. Yes Clean and inspect main control, if parts are damaged
Are the PCA and PCC PID values normal? or replace any malfunctioning parts.
NO.18 EXCESSIVE SHIFT SHOCK IS FELT WHEN UPSHIFTING AND DOWNSHIFTING [5R55S]
id0503c1804600
18 Excessive shift shock is felt when upshifting and downshifting
DESCRIPTION • Excessive shift shock felt when depressing accelerator pedal to accelerate at upshifting. During
cruising, excessive shift shock is felt when depressing accelerator pedal at downshifting.
• Shift shock may worsen when fail-safe is operating. The shift shock may worsen if the signal from the
accelerator pedal position sensor, TSS sensor, or OSS sensor has a malfunction.
1. Clutch slipped, burned
• Line pressure low, high
• Pressure control solenoid A malfunction
• Accelerator pedal position sensor misadjustment
POSSIBLE • TFT sensor malfunction
CAUSE • ISS sensor malfunction
• VSS signal malfunction
• IAT sendor malfunction
3. Poor hydraulic operation (Malfunction in range change)
• Low fluid pressure
4. Engine mounts installation
• Loose attaching bolts
• Worn parts
Note
05-03-20
1 Inspect the engine mounts for loose tightening Yes Go to the next step.
bolts or worn parts. No Readjust, tighten or replace engine mounts.
Are all engine mounts normal?
(See 05-13-4 MECHANICAL SYSTEM TEST No Repair or replace any malfunctioning parts.
[5R55S].)
Is stall speed normal?
the IDS/PDS. No Repair or replace any malfunctioning parts.
• APP
ohms?
5 Inspect the PCA, PCB and PCC PID values. Yes Clean and inspect main control, if parts are damaged
NO.19 EXCESSIVE SHIFT SHOCK ON TORQUE CONVERTER CLUTCH (TCC) [SRSSS]
19 Excessive shift shock on torque converter clutch (TCC)

DESCRIPTION • Strong shock is felt when TCC is engaged.
POSSIBLE • The troubleshooting flow is the same as No.16 "JUDDER UPON TORQUE CONVERTER CLUTCH
CAUSE (TCC) OPERATION".
05-03-21
NO.20 NOISENIBRATION FORWARD OR REVERSE [SRSSS]
id0503c1814600

DESCRIPTION • Transmission noisy in all positions and ranges.
• Improper fluid level
• Transmission shift cable and bracket damaged or misadjusted.
• Digital transmission range (TR) sensor damaged
• Line pressure high/low
• One-way clutch
POSSIBLE • Transmission oil cooler
CAUSE • Gear
• Torque converter
Note
• Before following the troubleshooting steps, make sure that the Automatic Transmission On-Board
Diagnostic and Automatic Transmission Basic Inspection are conducted.
1 FLUID Yes Adjust to proper level.
• Does the following problem exist? No Go to Step 2.
• Improper level.
2 SHIFT LINKAGES (INTERNAL! Yes Inspect for damage. Readjust as required.
EXTERNAL) Repair all damaged components.
After repairing linkages, readjust the digital TR sensor.
• Does the following problem exist?
(See 05-13-22 DIGITAL TRANSMISSION RANGE (TR)
• Transmission shift cable and bracket
SENSOR REMOVAUINSTALLATION [5R55S].)
damaged or misadjusted. Digital
transmission range (TR) sensor damaged. No Go to Step 3.
3 IMPROPER PRESSURES Yes Perform line pressure and stall speed tests.
• Does the following problem exist? If pressure is high/low, check the pump assembly.
• Improper band/clutch application pressures, No Go to Step 4.
line pressure high/low.
4 PUMP ASSEMBLY Yes Inspect and repair as required.
• Do any of the following problems exist? Tighten screws to specification.
• Internal leakage, cavitations. No Go to Step 5.
• Screws out of torque specification.
5 OVERDRIVE ONE-WAY CLUTCH Yes Repair one-way clutch.
ASSEMBLY No Go to step 6.
• Does the following problem exist?
• One-way clutch damaged, worn,
misassembled.
6 REAR ONE-WAY CLUTCH ASSEMBLY Yes Repair one-way clutch.
• One-way clutch damaged, worn,
misassembled.
7 OTHER Yes Relocate transmission oil cooler lines or fill tube properly.
• Transmission oil cooler lines fill tube
grounding.
8 GEAR Yes Repair planetary gear assemblies.
• Gear noise.
9 TORQUE CONVERTER CLUTCH Yes Go to symptom troubleshooting NO.16 "JUDDER UPON
ASSEMBLY TORQUE CONVERTER CLUTCH (TCC) OPERATION".
• Does the following problem exist? No Go to symptom troubleshooting "SYMPTOM
• Torque converter internal malfunction TROUBLESHOOTING ITEM TABLE".
preventing lockup piston application.
05-03-22
NO.21 NO ENGINE BRAKING IN 1 GR POSITION OF MANUAL 1 RANGE [5R55S]
id0503c1814000
21 No engine braking in 1 GR position of manual 1 range
DESCRIPTION • Engine speed drops to idle but vehicle coasts when accelerator pedal is released when in 1GR of
manual 1 range at low vehicle speed.
• Pressure control solenoid A and B malfunction
POSSIBLE • Reverse servo malfunction
CAUSE • Reverse band malfunction
Note
• Do the following symptoms concurrently Yes Go to symptom troubleshooting NO.14 "ENGINE FLARES
occur? UP OR SLIPS WHEN UPSHIFTING OR DOWNSHIFTING"
- Engine flares up or slips during or NO.15 "ENGINE FLARES UP OR SLIPS WHEN
acceleration. ACCELERATING VEHICLE".
- Engine flares up or slips when shifting. No Repeat the basic inspection and repair or replace any
malfunctioning parts according to the inspection result.
05-03-23
NO.22 TRANSMISSION OVERHEATS [5R55S]
id0503c1814100
22 Transmission overheats
DESCRIPTION • Burnt smell emitted from transmission.

• Smoke emitted from transmission.
• The malfunction maybe restriction in the cooling system. The technician needs to diagnose the
complete cooling system. Include coolers, line, and hoses. In addition, overheating of the transmission
may be caused by a malfunction of the TFT sensor.
1. Burning (TCC)
• Line pressure
• Improper fluid level
2. Oil cooler malfunction (Foreign material mixed ATF)
3. Excessive amount of ATF
POSSIBLE • TCC control solenoid malfunction
CAUSE • Pressure control solenoid A malfunction
• Excessive tow load
• Vehicle over load
• Engine concern
Note
1 Inspect oil cooler pipes for bending, damage, Yes Go to the next step.
corrosion or kinks. No Replace any malfunctioning parts.
Are the oil cooler pipes normal?
2 Is the line pressure normal. Yes Go to the next step.
(See 05-13-4 MECHANICAL SYSTEM TEST No Repair or replace any malfunctioning parts.
[5R55S].)
the IDS/PDS. No Repair or replace any malfunctioning parts.
• TFT
• TCC
• PCA
• PCB
• PCC
CO and body ground, and between TCM ground Reconnect the TCM connector.
ohms?
6 Inspect pressure control solenoid A, Band C. Yes Clean and inspect main control and the thermo static
(See 05-13-34 SOLENOID VALVE bypass valve. If parts are damaged, replace main control.
05-03-24
NO.23 ENGINE STALLS WHEN SHIFTED TO D RANGE, OR IN R POSITION [SRSSS]
id0503c1814200
23 Engine stalls when shifted to D range, or in R position

DESCRIPTION • Engine stalls when shifting from N or P position to D range or R position at idle.
POSSIBLE • The malfunction is on the engine control side (i.e. Electronic throttle control system). Otherwise, the
CAUSE malfunction is in the TSS sensor (engine sometimes starts).
STEP INSPECTION AC,TION
1 Go to symptom troubleshooting No.10 "LOW Yes Repeat basic inspection and repair or replace any
IDLE/STALLS DURING DECELERATION". malfunctioning parts according to the inspection result.
Is the engine control system normal? (See OS-03-4 BASIC INSPECTION [SRSSS].)
No Repair or replace any malfunctioning parts according to the
inspection results.
• Ifthe vehicle repaired, the troubleshooting is completed .
• If the vehicle the not repaired or additional diagnostic information is not available, replace the TCM ..
NO.24 ENGINE STALLS WHEN DRIVING AT SLOW SPEEDS OR STOPPING [SRSSS]

id0503c1814300
24 Engine stalls when driving at slow speeds or stopping

DESCRIPTION • Engine stalls when brake pedal is depressed while driving at low speed or stopping.
. POSSIBLE • The malfunction on engine control side (e.g. Fuel injection control, Electronic throttle control system)
Otherwise, the malfunction is in the control valve body, TCC control solenoid or TCC and one-way
CAUSE
clutch.
Go to symptom troubleshooting No.1 0 "LOW Yes Go to the next step.
IDLE/STALLS DURING DECELERATION". No Repair or replace any malfunctioning parts according to
Is the engine control system normal? inspection results.
2 Go to symptom troubleshooting No.S "ENGINE Yes Repeat the basic inspection and repair or replace any
STALLS-AFTER START/AT IDLE". malfunctioning parts according to the inspection result.
Is the engine control system normal? (See OS-03-4 BASIC INSPECTION [SRSSS].)
No Repair or replace any malfunctioning parts according to the
inspection results.
NO.2S STARTER DOES NOT WORK [SRSSS]

id0503c1814400
25 Starter does not work

DESCRIPTION • Starter does not work even when in P or N position.
• Selector lever misadjustment
• Digital TR sensor misadjustment
• Open or short circuit in digital TR sensor
POSSIBLE • TCM malfunction
CAUSE • Vehicle harnesses
• Shift cable misadjustment
• Fluid pump
• Torque converter
05-03-25
CLUTCH .................. 05-10 MANUAL TRANSMISSION

MANUAL TRANSMISSION [S15M-D, S15MX-D] ........ 05-118
[R15M-D] ................ 05-11A TECHNICAL DATA .......... 05-50
SERVICE TOOLS ........... 05-60
05-10 CLUTCH
CLUTCH LOCATION INDEX ..•....... 05-10-2 . CLUTCH RELEASE CYLINDER
GENERAL PROCEDURES REMOVAUINSTALLATION •.......•. 05-10-10
(CLUTCH) .••......••.•.••••.••.. 05-10-3 CLUTCH RELEASE CYLINDER
CLUTCH FLUID INSPECTION .•.....• 05-10-3 DISASSEMBLY/ASSEMBLY .•....... 05-10-11
CLUTCH FLUID AIR CLUTCH UNIT
BLEEDING/REPLACEMENT ..•..... 05-10-3 REMOVAUINSTALLATION .••.•....• 05-10-12
CLUTCH PEDAL ADJUSTMENT ...... 05-10-4 CLUTCH COVER INSPECTION ...•.•.. 05-10-16
CLUTCH PEDAL CLUTCH DISC INSPECTION •..•...... 05-10-17
REMOVAUINSTALLATION ..•..••..• 05-10-5 CLUTCH RELEASE COLLAR
CLUTCH PEDAL INSPECTION ••.•..•.•..........•. 05-10-17
DISASSEMBLY/ASSEMBLY ••.•..... 05-10-6 PILOT BEARING INSPECTION .•...••. 05-10-18
CLUTCH MASTER CYLINDER FLYWHEEL INSPECTION [R15M-D] .••. 05-10-18
REMOVAUINSTALLATION .......••. 05-10-6 DUAL-MASS FLYWHEEL
CLUTCH MASTER CYLINDER INSPECTION [S15M-D, S15MX-D] ...• 05-10-19
DISASSEMBLY/ASSEMBLY ..•..••.. 05-10-8
05-10-1
CLUTCH
CLUTCH LOCATION INDEX
dcf051016003w01
R15M-D
DBG510ZWB006
1 Clutch pipe 6 Clutch unit

(See 05-10-3 GENERAL PROCEDURES (See 05-10-12 CLUTCH UNIT REMOVAU
(CLUTCH).) INSTALLATION.)
2 Brake fluid reservoir tank 7 Clutch cover
(See 05-10-3 CLUTCH FLUID INSPECTION.) (See 05-10-16 CLUTCH COVER INSPECTION.)
(See 05-10-3 CLUTCH FLUID AIR BLEEDING/ 8 Clutch disc
REPLACEMENT.) (See 05-10-17 CLUTCH DISC INSPECTION.)
3 Clutch pedal 9 Clutch release collar
(See 05-10-4 CLUTCH PEDAL ADJUSTMENT.) (See 05-10-17 CLUTCH RELEASE COLLAR
(See 05-10-5 CLUTCH PEDAL REMOVAU INSPECTION.)
INSTALLATION.) 10 Pilot bearing
4 Clutch master cylinder (See 05-10-18 PILOT BEARING INSPECTION.)
(See 05-10-6 CLUTCH MASTER CYLINDER 11 Flywheel [R15M-D] or dual-mass flywheel [S15M-D,
REMOVAUINSTALLATION.) S15MX-D]
(See 05-10-8 CLUTCH MASTER CYLINDER (See 05-10-18 FLYWHEEL INSPECTION [R15M-D].)
DISASSEMBLY/ASSEMBLY.) (See 05-10-19 DUAL-MASS FLYWHEEL
5 Clutch release cylinder INSPECTION [S15M-D, S15MX-D].)
(See 05-10-10 CLUTCH RELEASE CYLINDER
05-10-2
CLUTCH
GENERAL PROCEDURES (CLUTCH)
dcf051016003w02
Caution
• Fluid will damage painted surfaces. Be careful not to spill any fluid on painted surfaces. If fluid
does get on painted surfaces, wipe it off immediately.
Note
• If any hydraulic related parts of the clutch system are removed during the procedure, add clutch fluid
(brake fluid), bleed air from the system and inspect for leakage after the procedure has been completed.
1. Remove the clutch pipe using the SST (4902597708).

2. Install the clutch pipe using a torque wrench and the SST (49 0259 7708).
CLUTCH FLUID INSPECTION

dcf051016010w01
1. Inspect whether the fluid level in the clutch fluid (brake fluid) reservoir tank is between MIN and MAX.
CLUTCH FLUID AIR BLEEDING/REPLACEMENT

dcf051016010w02
Caution
• Fluid will damage painted surfaces. Be careful not to spill any on painted surfaces. If fluid does get
on painted surfaces, wipe it off immediately.
• Keep the fluid level in the reserve tank at 3/4 full or more during air bleeding.
Note
• When replacing the fluid, drain the old fluid, fill the reserve tank with new fluid and then perform Steps 1-
7 below.
Specified fluid
SAE J1703, FMVSS 116 DOT-3
1. Remove the bleeder cap from the clutch release cylinder, and connect a vinyl hose to the bleeder plug.
2. Place the other end of the vinyl tube in a clear container, and fill fluid in the container during air bleeding.
3. Working with two people, one should depress the clutch pedal a few times and then depress and hold the pedal
down.
4. While the clutch pedal is being held down, the other person should loosen the bleeder screw using the SST,
and bleed any fluid containing air bubbles. Once completed, tighten the bleeder screw.
5. Continue to perform Steps 3 and 4 until no air comes from the vinyl hose.
6. Tighten the bleeder screw using the SST. ,------;;;-----;;....,..----,--------------,
Tightening torque
5.9-8.8 N·m {61-89 kgf·cm, 53-77 in·lbf}
7. Fill the reserve tank to MAX with the

recommended fluid.
8. Perform the following inspections:
• Clutch operation
• Fluid leakage
• Fluid level
DBG510ZWB002
05-10-3
CLUTCH
CLUTCH PEDAL ADJUSTMENT
dcf051 041 030w01
Clutch Pedal Stroke Inspection/Adjustment

1. Measure the clutch pedal stroke.
• If there is any malfunction, loosen locknut A
and adjust the pedal stroke by clutch switch B.
Tighten locknut A after adjustment.
Clutch pedal stroke

152 mm {5.98 in}
J
1,,-_.... I
',I'
'/ I
/ /'
I' I
1/ / I ,I
/1 I I"
/1 / I 1/
1/ I I /'
1/ I / 1/
1/ I I / '
~I
", ,,,
" ' J
", ",
", ",
", ",
I I I II
~ \ \ \.
\.\,'~"\.
\ ,'....- ' \. ('ill.
, ' I III
........ ',III
"i i ,
"1/
N·m
{kgf·cm, in·lbf}
DBG510ZWB013
Clutch Pedal Play Inspection/Adjustment

1. Lightly depress the clutch pedal by hand until
clutch resistance is felt and then measure the \
pedal play. \
\
\
\ ,
Clutch pedal play
5-15 mm {0.20-0.59 in}
Clutch pedal push rod play (Reference value)

0.1-0.5 mm {0.004-0.020 in}
2. If it is not within the specification, loosen locknut

C and turn push rod D to adjust the pedal play.
3. Remeasure the pedal play and, if it is within the
specification, tighten locknut C.
11.76-16.66 N·m
{120.3-169.8,104.4-147.4} {kgf.cm, in·lbf}
DBG510ZWB014
05-10-4
CLUTCH
Clutch Disengagement Point Inspection
2. Without depressing the clutch pedal, move the shift lever slowly to the reverse position until gear noise is heard
and hold the lever in that position.
3. Slowly depress the clutch pedal and hold at the point where the gear noise stops (clutch disengagement point).
4. Measure distance A (from pedal not depressed to
clutch disengagement point) and verify that it is
I
Clutch disengagement stroke (Reference I
I
value) [R15M-D] I
I
A: 100-130 mm {3.94-5.11 in} I
Clutch disengagement stroke (Reference

value) [S15M-D, S15MX-D]
A: 110-125 mm {4.34-4.92 in}
CHU0510W006
Clutch Switch Inspection

2. Disconnect the clutch switch connector.
3. Verify continuity as indicated in the table.
0---0 : Continuity
Terminal
Condition
A 8
Clutch pedal
depressed
Clutch pedal
released
DBG510ZWBOOl
CHU0510W007
• If there is any malfunction, replace the clutch switch.
CLUTCH PEDAL REMOVAL/INSTALLATION

dcf051041030w02
1. The clutch pedal is mounted on the bracket integrated with the brake pedal and accelerator pedal. Refer to
section 01, INTAKE AIR SYSTEM, ACCELERATOR PEDAL REMOVAUINSTALLATION for the brake pedal
removal/installation. (See 01-13A-9 ACCELERATOR PEDAL COMPONENT REMOVAUINSTALLATION [WL-
3].) (See 01-138-11 ACCELERATOR PEDAL COMPONENT REMOVAUINSTALLATION [WL-C, WE-C].)
05-10-5
CLUTCH
CLUTCH PEDAL DISASSEMBLY/ASSEMBLY
dcf051 041 030w03
1. Remove the accelerator pedal component. (See 01-13A-9 ACCELERATOR PEDAL COMPONENT REMOVAL/
INSTALLATION [WL-3].) (See 01-13B-11 ACCELERATOR PEDAL COMPONENT REMOVAL/INSTALLATION
[WL-C, WE-C].)
4. Inspect and adjust the clutch pedal. (See 05-10-4 CLUTCH PEDAL ADJUSTMENT.)
7
11.76-16.66
{120.3-169.8,104.4-147.4}
N·m
{kgf·cm, in·lbf}
DBG510ZWB015
1 Clutch switch 6 Bush

2 Nut 7 Nut
3 Stopper rubber 8 Push rod
4 Retaining ring 9 Fork
5 Pin 10 Pedal pad
CLUTCH MASTER CYLINDER REMOVAUINSTALLATION

dcf051041990w01
Caution
• Fluid will damage painted surfaces. Be careful not to spill any fluid on painted surfaces. If it is

3. Bleed the air from the system.
(See 05-10-3 CLUTCH FLUID AIR BLEEDING/REPLACEMENT.)
4. Inspect and adjust the clutch pedal.
(See 05-10-4 CLUTCH PEDAL ADJUSTMENT.)
05-10-6
CLUTCH
R1SM-D
2 18.6-25.5 {1.90-2. 60 , 13.7-18.8}
------;-;---
16-22 16}
1 {1.7-2.2,12-
mJ*
*49 0259 770B N·m {kgf·m, ft·lbf}
----I 1-=:::;~lrC:CYViirln~~de~r======~==
----- DBG510ZWB020
I -3 ClutC.h master _ __ 1
I 4 . Packing
S15M-D,
S1 SMX-D
==---------
,
18.6-25.5 37-18.8}
{1.9D-2.60, 1 .
/
5m
()fo~ j~-\&
mJ*
16--"
{1.7-2.2,12-
16)
1m
*49 0259 770B
( DBG510ZWB016
\,
1 IClutch
Hose clip 4 IClutc.h master cylinder
2 pipe 1 5 Packing
I 3 Nut I
05-10-7
CLUTCH
CLUTCH MASTER CYLINDER DISASSEMBLY/ASSEMBLY
dcf051041990w02
1. Disassembre in the order indicated in the table.

R15M-D
o ~
~
...-® 83.3-112.7 N·m
{8.5-11.4kgf.m,61.5-83.1 tt.lbf}
DBG510ZWB021
1 Snap ring 7 Reservoir

(See 05-10-9 Snap Ring Disassembly/Assembly 8 Bushing
Note.)
9 Joint bolt
2 Piston
10 Packing
3 Spacer
11 One-way valve piston
4 Primary cup
12 Return spring
5 Return spring
13 One-way valve pin
6 Tank cap
14 Clutch master cylinder body
05-10-8
CLUTCH
S1SM-D, S1SMX-D
7 83.3-112.7 N·m
{4.50-11.49 kgf·m, 61.44-83.12 ft·lbf}
iii 1 11 9
1110 0
~
iii /~
1I1i1~
39.0-53.9 N·m ~ ~
{3.98-5.49 kgf·m, 28.8-39.7 ft·lbf} ~
DBG510ZWB017
1 Hose clip 9 One-way valve piston

2 Reserve tank hose 10 Return spring
3 Joint 11 One"way valve pin
4 Bushing 12 Snap ring
5 Clutch damper (See 05-10-9 Snap Ring Disassembly/Assembly
Note.)
6 Packing
13 Piston component
7 Joint bolt
14 Clutch master cylinder body
8 Packing
Snap Ring Disassembly/Assembly Note

1. While pressing the piston in with a cloth-wrapped
pin punch to protect the push rod contacting
surface, remove/install the snap ring.
CHU0510W003
05-10-9
CLUTCH
CLUTCH RELEASE CYLINDER REMOVAUINSTALLATION
dcf051041920w01
Caution
• Fluid will damage painted surfaces. Be careful not to spill any fluid on painted surfaces. If fluid
does get on painted surfaces, wipe it off immediately.

(See 05-10-3 CLUTCH FLUID AIR BLEEDING/REPLACEMENT.)
4. Inspect and adjust the clutch pedal.
(See 05-10-4 CLUTCH PEDAL ADJUSTMENT.)
21.6-26.5 N·m
{2.21-2.70 kgf·m,
16.0-19.5 It.lbf}
mJ'2
'49 0259 770B
DBG510ZWB003
Return spring (815M-D, 815MX-D) 3 IClutch release cylinder

Clutch hose
05-10-10
CLUTCH
CLUTCH RELEASE CYLINDER DISASSEMBLY/ASSEMBLY
dcf05104192Ow02

5.9-8.8 N·m {61-89 kgf·cm, 53-77 in·lbf}
DBG510ZWB004
1 Boot 5 Bleeder cap

2 Push rod 6 Bleeder screw
3 Piston, piston cup component 7 Clutch release cylinder body
4 Return spring
05-10-11
CLUTCH
CLUTCH UNIT REMOVAUINSTALLATION
dcf051016000w01
R15M-D:
• 96.1-102.9 {9.80-10.49, 70.88-75.89}
S15M-D, S15MX-D:
151.3-161.1 {15.43-16.42, 111.6-118.8}
R15M-D
8 mil
S15M-D, S15MX-D
':l) R15M-D
~ > ~
DBG510ZWB005
1 Return spring (S15M-D, S15MX-D) 8 Clutch disc

(See 05-10-13 Clutch Cover and Disc Removal
2 Clutch release cylinder
Note.) .
(See 05-10-15 Clutch Disc Installation Note.)
9 Pilot bearing [R15M-D]
3 Manual transmission
(See 05-10-13 Pilot Bearing Removal Note [R15M-
(See 05-11A-5 TRANSMISSION REMOVAU
D].)
INSTALLATION [R15M-Dj.)
(See 05-10-14 Pilot Bearing Installation Note
(See 05-11 B-5 TRANSMISSION REMOVAIJ
[R15M-D].)
INSTALLATION [S15M-Dj.)
(See 05-11 B-1 0 TRANSMISSION AND TRANSFER 10 Flywheel [R15M-D] or dual-mass flywheel [S15M-D,
REMOVAUINSTALLATION [S15MX-Dj.) S15MX-D]
(See 05-10-14 Flywheel [R 15M-D] or Dual-Mass
4 Boot
Flywheel [S15M-D, S15MX-D] Removal Note.)
5 Clutch release collar (See 05-10-15 Flywheel [R15M-D] or Dual-Mass
(See 05-10-17 CLUTCH RELEASE COLLAR Flywheel [S15M-D, S15MX-D] Installation Note.)
INSPECTION.)
6 Clutch release fork
7 Clutch cover
(See 05-10-13 Clutch Cover and Disc Removal
Note.)
(See 05-10-15 Clutch Cover Installation Note.)
05-10-12
CLUTCH
Clutch Cover and Disc Removal Note
Caution
• When replacing components, always replace as a complete set. [S15M-D, S15MX-D]
• Due to the automatic adjustment function of clutch cover, if the old cover assembly is reused, it
must be reinstalled together with its original clutch disc. [S15M-D, S15MX-D]
1. Install the SSTs.

2. Loosen each bolt one turn at a time in a crisscross pattern until spring tension is released.
3. Remove the clutch cover and disc.
DBG510ZWB008
Pilot Bearing Removal Note [R15M-D]
Note
• The pilot bearing does not need to be removed unless you are replacing it.
1. Use the SST to remove the pilot bearing.
ADJ4920W005
05-10-13
CLUTCH
Pilot Bearing Installation Note [R15M-D]
1. Use the SSTs to install the pilot bearing.
I I •
..
DBG510ZWB018
ENGINE SIDE TRANSMISSION SIDE

+
PILOT BEARING
0-0.2 mm {0.0-0.0078 in}
DBG510ZWB019
Flywheel [R15M-D] or Dual-Mass Flywheel [S15M-D, S15MX-D] Removal Note

1. Hold the flywheel or dual-mass flywheel using the SST.
2. Remove the bolts evenly and gradually in a crisscross pattern.
3. Remove the flywheel or dual-mass flywheel. ,----------------------,
4. Inspect for oil leakage from the crankshaft rear oil
seal.
• If there is any malfunction, replace the • I
crankshaft rear oil seal.
(See 01-10A-17 REAR OIL SEAL
REPLACEMENT [WL-3].)
(See 01-108-18 REAR OIL SEAL
REPLACEMENT [WL-C, WE-C].)
DBG510ZWB009
05-10-14
CLUTCH
Flywheel [R15M-D] or Dual-Mass Flywheel [S15M-D, S15MX-D] Installation Note
1. Clean the crankshaft thread holes.
2. Install the flywheel or dual-mass flywheel to the crankshaft.
3. Hand-tighten the flywheel lock bolts or dual-mass flywheel lock bolts.
4. Install the SST to the flywheel or dual-mass ,---------------------,
flywheel.
5. Gradually tighten the flywheel lock bolts or dual-
mass flywheel lock bolts in a crisscross pattern.
Tightening torque
R15M-D: 96.1-102.9 N·m {9.80-10.49
kgf·m, 70.88-75.89 ft.lbf}
S15M-D, S15MX-D: 151.3-161.1 N·m
{15.43-16.42 kgf·m, 111.6-118.8 ft·lbf}
DBG510ZWB010
Clutch Disc Installation Note

1. Hold the clutch disc position using the SST.
ADJ4920W004
Clutch Cover Installation Note

1. Install the SSTs.
2. Tighten the bolts evenly and gradually in a
crisscross pattern.
Tightening torque • I
R15M-D: 17.6-26.5 N·m {1.80~2.70 kgf·m,
13.0-19.5 ft.lbf} , .
S15M-D, S15MX-D: 25.0-33.0 N·m {2.55-
3.36 kgf.m, 18.5-24.3 ft.lbf}
DBG510ZWB011
05·10-15
CLUTCH
CLUTCH COVER INSPECTION
dcf051 01641 Ow01
1. Measure the wear of the diaphragm spring

fingers.
replace the clutch cover.
Clutch disc maximum depth

0.6 mm {0.024 in}
B3E0510W023
2. Measure the flatness of the pressure plate with a

straight edge and a feeler gauge.
Clutch cover maximum clearance

0.3 mm {0.012 in}
3. When checking the diaphragm spring fingers,

mount a dial indicator on the cylinder block.
B3E0510W024
4. Rotate the flywheel or dual-mass flywheel and

check for misaligned diaphragm spring fingers.
Clutch cover maximum height difference

1.0 mm {0.039 in}
DBG510ZWB012
05-10-·16
CLUTCH
CLUTCH DISC INSPECTION
dcf05101646Ow01
1. Remove the clutch disc.

2. Inspect the lining surface for discoloration and grease/oil contamination.
3. Inspect the torsion spring for weakness and the rivet for looseness.
4. Using a vernier caliper, measure the depth ,-----------------------,
between the lining surface and the rivet head.
Clutch disc minimum depth

0.3 mm {0.012 in}

replace the clutch disc.
CHU0510W027
5. Measure the clutch disc runout using a dial

gauge.
Clutch disc maximum runout

0.7 mm {0.028 in}

replace the clutch disc.
6. Install the clutch disc.
CLUTCH RELEASE COLLAR INSPECTION
Caution
• Do not clean the clutch release collar with cleaning fluids or a steam cleaner because it is filled
with grease.
1. Remove the clutch release collar.

2. Turn the collar while applying force in the axial
direction, and inspect for sticking, excessive
resistance, and an abnormal noise.
• If there is any malfunction, replace the clutch
release collar.
3. Install the clutch release collar.
B3E0510W026
05-10-17
CLUTCH
PILOT BEARING INSPECTION
dcf051011501w01
1. Without removing the pilot bearing, turn the

bearing while applying force in the axial direction.
• If there is any malfunction, replace the pilot
bearing.
DBG510ZWB023
FLYWHEEL INSPECTION [R15M-D]

dcf05101150Ow01
1. Remove the flywheel.
Note
using sandpaper.
contacts the clutch disc with the flywheel
installed to the crankshaft.
2. Inspect the surface that contacts the clutch disc

for scratches, nicks, and discoloration.
3. Inspectthe ring gear teeth for damage and wear.
4. Install the flywheel.
DBG510ZWB024
5. Measure the runout of the surface that contacts

the clutch disc using a dial gauge.
Flywheel maximum runout [R15M-D]

0.1 mm {0.004 in}

replace the flywheel.
05-10-18
CLUTCH
DUAL-MASS FLYWHEEL INSPECTION [S15M-D, S15MX-D]
dcf051011500w02
Caution
• Do not rework the dual-mass flywheel if it is distorted.
• Do not clean the dual-mass flywheel with any kind of fluid. Clean the dual-mass flywheel with a dry
cloth only.
• Do not clean the gap between the primary and secondary mass. Only clean the bolt connection
surface and the clutch surface.
1. Remove the dual-mass flywheel.
Note
using sandpaper.
contacts the clutch disc with the dual-mass
flywheel installed to the crankshaft.
2. Inspect the dual-mass flywheel.

Cracks
Worn ring gear teeth
Chipped or cracked ring gear teeth
Surface that contacts the clutch disc for
scratches, nicks, and discoloration.
mass flywheel.
C3U0510W004
3. Verify that the center of the dual-mass flywheel

does not move. .
(1) Rotate the dual-mass flywheel or attempt to
move it up and down, and left and right to
verify that the center of the dual-mass
flywheel does not move.
• If there is any movement as indicated by
the arrows in the figure, replace the dual-
mass flywheel with a new one.
4. Verify that the secondary mass rotates by 15

teeth or more.
• If it rotates by 15 teeth or more, replace the
dual-mass flywheel.
D3E510ZW8001
05-10-19
CLUTCH
5. Inspect for locating dowels touching the primary
~-~·------J--L-D7--=
mass of the dual-mass flywheel.
Caution
• Make sure that the three locating dowels
are installed.
• If the locating dowels are touching the primary

~~~~~~~~~~~============~~=
mass of the dual-mass flywheel, replace the
dual-mass flywheel with a new one. -==-- -
6. Visually inspect the secondary mass.
• If there is any damage, replace the dual-mass 1linnnnnnnnr B3E0510W056
flywheel.
7. Visually inspect the ring gear on the dual-mass
flywheel. F.lING GEAR
flywheel.
D3E510ZW8002
8. Inspect the welded area of the dual-mass

flywheel for grease leakage.
• If there is grease leakage, replace the dual-
mass flywheel.
9. Inspect the dual-mass flywheel runout.
Dual-mass flywheel maximum runout [S1SM-

D, S1SMX-D]
1.S mm {O.OS9 in}
• If it is more than the maximum specification,

replace the dual-mass flywheel.
D3E510ZW8007
05-10-20
CLUTCH
10. Inspect the dual-mass flywheel for the amount of
=1
guide pin projection.
dual-mass flywheel.
11 mm {D.433D}
=
D3E510ZWB005
11. Rotate the secondary mass left and right and

verify that it rotates within a range of five teeth
without resistance.
mass flywheel.
12. Inspect the dual-mass flywheel for cracks.
• If there are cracks, replace the dual-mass
flywheel.
D3E510ZWB006
05-10-21
05-118 MANUAL TRANSMISSION [S1SM-D, S1SMX-D]

MANUAL TRANSMISSION LOCATION VEHICLE SPEED SENSOR (VSS)
INDEX [S15M-D, S15MX-D] .......•. 05-118-2 INSPECTION [S15M-D] .•....•...•.. 05-118-5
NEUTRAL SWITCH TRANSMISSION
REMOVAUINSTALLATION REMOVAUINSTALLATION
[S15M-D, S15MX-D] ..••.•••...•.•• 05-118-3 [S15M-D] ...•••...•..•.....•...... 05-118-5
TRANSMISSION OIL INSPECTION TRANSMISSION AND TRANSFER
[S15M-D, S15MX-D] .•......••..•.. 05-118-3 REMOVAUINSTALLATION
TRANSMISSION OIL REPLACEMENT [S15MX-D] •••.••.•..•............ 05-118-10
[S15M-D, S15MX-D] •.••...•...•.•. 05-118-4 INSPECTION AFTER TRANSMISSION
OIL SEAL (EXTENSION HOUSING) INSTALLATION [S15M-D] ...••..••.. 05-118-12
REPLACEMENT [S15M-D] .••.•.••.. 05-118-4 INSPECTION AFTER TRANSMISSION
VEHICLE SPEED SENSOR (VSS) AND TRANSFER INSTALLATION
REMOVAUINSTALLATION [S15MX-D] ...•....••...•••....... 05-118-12
[S15M-D] .•........•......••..•.. 05-118-5
05-118-1
MANUAL TRANSMISSION LOCATION INDEX [S15M-D, S15MX-D]
dcfOS110000OwOS
S15M-D
DBG511 BWB001
Transmission oil 2 Oil seal (extension housing)

(See 05-118-3 TRANSMISSION OIL INSPECTION (See 05-118-4 OIL SEAL (EXTENSION HOUSING)
[S15M-D, S15MX-D].) REPLACEMENT [S15M-D].)
(See 05-118-4 TRANSMISSION OIL
REPLACEMENT [S15M-D, S15MX-D].)
05-118-2
MANJJAL TRANSMISSION [S1SM-D, S1SMX-D]
3 Transmission 4 Neutral switch

(See 05-11 B-5 TRANSMISSION REMOVAU (See 05-118-3 NEUTRAL SWITCH REMOVAU
INSTALLATION [S15M-D].) INSTALLATION [S15M-D, S15MX-D].)
(See 05-11 B-1 0 TRANSMISSION AND TRANSFER 5 Vehicle speed sensor
REMOVAUINSTALLATION [S15MX-D].) (See 05-118-5 VEHICLE SPEED SENSOR (VSS)
(See 05-11B-12 INSPECTION AFTER REMOVAUINSTALLATION [S15M-D].)
TRANSMISSION INSTALLATION [S15M-DJ.) (See 05-11 B-5 VEHICLE SPEED SENSOR (VSS)
(See 05-11 B-12 INSPECTION AFTER INSPECTION [S15M-DJ.)
TRANSMISSION AND TRANSFER INSTALLATION
[S15MX-D].)
NEUTRAL SWITCH REMOVAUINSTALLATION [S15M-D, S15MX-D]

dcf051100000w06

2. Disconnect the neutral switch connector.
3. Remove the neutral switch.
4. Install the new neutral switch and a new packing
to the transmission case.
Tightening torque
25-34 N·m {2.6-3.4 kgf.m, 19-25 ft.lbf}
5. Connect the neutral switch connector.

S1SMX-O
DBG511 BWB002
TRANSMISSION OIL INSPECTION [S15M-D, S15MX-D]

dcf051127001w03

2. Remove oil filler plug.
• If the oil is not near the brim of the plug port,
add the specified amount and type of oil.
Transmission case oil [S15M-D, S15MX-D]

4. Install oil filler plug and a new washer.
Tightening torque OIL FILLER PLUG

40-59 N·m {4.1-6.0 kgf·m, 30-43 ft·lbf}
DBG511 BWB004
05-118-3
TRANSMISSION OIL REPLACEMENT [S15M-D, S15MX-D]
dcf05112?001w04

2. Remove oil filler plug and drain plug, and then
drain the oil.
3. Clean drain plug.
4. Install drain plug and a new washer.
Tightening torque
40-59 N·m {4.1-6.0 kgf.m, 30-43 ft·lbf}
OIL DRAIN PLUG

DBG511 BWB005
5. Add the specified amount and type of oil through

the plug port for oil filler plug to near the brim of
the port.

Type: Mercon® Multi-purpose AFT XT-2-QDX .
Capacity (approx. quantity): 3.55 L {3.75 US
qt, 3.12 Impqt}
DBG511 BWB006
6. Install oil filler plug and a new washer.
Tightening torque
40-59 N·m {4.1-6.0 kgf.m, 30-43 ft.lbf}
OIL FILLER PLUG

DBG511 BWBOO?
OIL SEAL (EXTENSION HOUSING) REPLACEMENT [S15M-D]

dcf05111?335w02

2. Drain the transmission oil.
(See 05-118-4 TRANSMISSION OIL REPLACEMENT [S15M-D, S15MX-D].)
3. Remove the propeller shaft.
(See 03-15-2 PROPELLER SHAFT REMOVAUINSTALLATION.)
4. Remove the oil seal using a flathead screwdriver. I----~~=i====:------l
DBG511 BMB003
05-118-4
6. Tap a new oil seal into the case using the SST.
8. Add transmission oil.
(See 05-118-4 TRANSMISSION OIL
REPLACEMENT [S15M-D, S15MX-D].)
VEHICLE SPEED SENSOR (VSS) REMOVAL/INSTALLATION [S1SM-D]

dcf051117400w03
Caution

2. Disconnect the VSS connector.
3. Remove the VSS.
4. Apply the specified oil to a new O-ring and install
it on a VSS.
5. Install the VSS.
Tightening torque
7.8-11.0 N·m {80-112 kgf·cm, 70-97
in.lbf}
6. Connect the VSS connector.

VEHICLE SPEED SENSOR (VSS) INSPECTION [S1SM-D]

1. Remove the VSS. (See 05-118-5 VEHICLE SPEED SENSOR (VSS) REMOVAL/INSTALLATION [S15M-D].)
2. Measure voltage between terminals of the VSS
while the gear is turning.
Vehicle speed sensor (VSS) voltage [S1SM-D]

S V or less
• If the voltage is within the specification, the

VSS is normal. Repair the related wiring
harness.
• If the voltage is not within the specification
(tester needle does not move), replace the
VSS.
DBG511 BWB009
3. Install the VSS. (See 05-118-5 VEHICLE SPEED
SENSOR (VSS) REMOVAL/INSTALLATION
[S15M-D].)
TRANSMISSION REMOVAL/INSTALLATION [S1SM-D]

dcf05110000OW07

2. Remove the propeller shaft. (See 03-15-2 PROPELLER SHAFT REMOVAL/INSTALLATION.)
3. Remove the front pipe and oxidation catalytic converter. (See 01-158-2 EXHAUST SYSTEM REMOVAU
6. Perform the 'INSPECTION AFTER TRANSMISSION INSTALLATION', and verify that there is no abnormality.
(See 05-118-12 INSPECTION AFTER TRANSMISSION INSTALLATION [S15M-D].)
05-118-5
Except Hi-Rider
REGULAR CAB -!r.
o
7H10?~~
N
{80-112 kgf·cm,
70-99 in·lbf}
~ r=---
~
I
16
4Jr- 36.5-46.1
@
{3.73-4.70,
27.0-34.0}
DBG511 BWBOl 0
1 Shift lever knob 14 Back-up light switch connector

2 Console (regular cab) or boot panel (except regular 15 Vehicle speed sensor connector
cab) 16 Crossmember
(See 09-17-12 CONSOLE REMOVAU (See 05-11 B-8 Cross member Removal Note [Except
INSTALLATION.) Hi-Rider].)
3 Dust boot 17 Bolt
4 Change boot upper plate 18 Bolt
5 Boot 19 Transmission mount rubber .
6 Dust boot (See 05-11 B-8 Transmission Removal/installation
7 Gasket Note.)
8 Wave washer 20 Transmission mount bracket
(See 05-11 B-8 Transmission Removal/installation
9 Change bush Note.)
10 Shift lever
21 Transmission
11 Change seat (See 05-11 B-8 Transmission Removal/installation (-
12 Clutch release cylinder Note.)
13 Neutral switch connector 22 Front pipe bracket
05-118-6
Hi-Rider
--&
7.>-11.0?~ ~
N
{80-112 kgf·cm,
70-99 in·lbf}
~ =
15.7-22.5
{1.61-2.29,
11.6--16.5}
31.4-46.1
{3.21-4.70, I
~
23.2-34.0}
36.5-46.1
{3.73-4.70,
27.0-34.0}
DBG511BWB011
1 Shift lever knob 12 Clutch release cylinder

2 800t panel 13 Neutral switch connector
(See 09-17-12 CONSOLE REMOVAU 14 8ack-up light switch connector
INSTALLATION.)
15 Vehicle speed sensor connector
3 Dust boot
16 Crossmember
4 Change boot upper plate (See 05-118-8 Transmission Removal/installation
5 800t Note.)
6 Dust boot 17 Transmission mount rubber
7 Gasket (See 05-118-8 Transmission Removal/installation
Note.)
8 Wave washer
18 Transmission
9 Change bush
(See 05-118-8 Transmission Removal/installation
10 Shift lever Note.)
11 Change seat 19 Front pipe bracket
05-118-7
Crossmember Removal Note [Except Hi-Rider]
1. Remove the front parking brake cable as shown in
the figure. (See 04-12-6 PARKING BRAKE
CABLE REMOVAL/INSTALLATION [WL-C
2. Remove the crossmember.
Transmission Removal/installation Note
Warning
• Remove the transmission carefully, holding it steady. If the transmission falls it could be damaged
or cause injury.
Caution
• When removing/installing the transmission, do not move it more than necessary so as to prevent
part interference with the body.
1. Support the transmission securely using a transmission jack.

2. Set the transmission jack attachment into the ,...--------------=::-----------,
concavity of the transmission to prevent the
transmission from falling when it is tilted.
3. Remove the following parts:
Crossmember. (Hi-Rider)
Transmission mount rubber.
- Transmission mount bracket. (except Hi-
Rider)
4. Remove the transmission installation bolt.
DBG511 BWB015
5. Remove the transmission.

(1) Move the transmission to the rear.
(2) Change the inclination of the transmission
jack to raise the extension housing side.
(3) Lower the transmission jack until the
transmission does not interfere with the
member.
(4) Repeat Steps (1) to (3) (After Step (3) is
completed, a space will be available between
the extension housing and member).
(5) Wind a rope around the transmission after it
has tilted enough.
DBG511 BWB012
05-118-8
Warning
• Secure the transmission and
transmission jack properly using a rope,
otherwise the transmission could fall off,
causing damage or injury.
DBG511BWB013
(6) Move the transmission towards the engine

(After the inclination reaches a certain point,
the transmission can be moved towards
engine).
(7) Lower the transmission jack when the
extension housing moves to the position
where it does not interfere with the member.
DBG511BWB014
Shift Lever Component Installation Note
Note
• If the extension housing has been removed or the transmission has been disassembled and inspected,
always add the specified type and amount of transmission oil.
1. Add the specified type and amount of oil to the

shift control case.
Shift control case oil [S15M-D]

Capacity (approx. quantity): 220-260 ml
{220-260 cc, 13.42-15.86 cu in}
DBG511AWB014
05-118-9
. TRANSMISSION AND TRANSFER REMOVAUINSTALLATION [S1SMX-D]
dcf05110000Ow08

2. Remove the front propeller shaft and rear propeller shaft. (See 03-15-2 PROPELLER SHAFT REMOVAU
INSTALLATION.)
3. Remove the front pipe and oxidation catalytic converter. (See 01-158-2 EXHAUST SYSTEM REMOVAU
6. Perform the 'INSPECTION AFTER TRANSMISSION INSTALLATION', and verify that there is no abnormality.
(See 05-118-12 INSPECTION AFTER TRANSMISSION AND TRANSFER INSTALLATION [S15MX-D].)
7.8-11 N·m
14
I 36-S0
V {3.7-S.0,
27-36}
31.4-46.1
{3.21-4.70, 23.2-34.0}
43-S4 A
{4.4-5.S,
32-39}

DBG511BWB018
1 Shift lever knob 5 Boot

2 Boot panel 6 Dust boot
(See 09-17-12 CONSOLE REMOVAU 7 Gasket
INSTALLATION.)
8 Wave washer
3 Dust boot
9 Change bush
4 Change boot upper plate
10 Shift lever
05-118-10
11 Transfer shift lever 20 Crossmember

12 Change seat (See 05-118-11 Transmission Removal/installation
Note.)
13 Clutch release cylinder
(See 05-10-10 CLUTCH RELEASE CYLINDER 21 Transmission
REMOVAUINSTALLATION.) (See 05-118-11 Transmission Removal/installation
Note.)
14 Transfer under cover
22 Transmission mount component
15 Neutral switch connector
23 Front pipe bracket
16 8ack-up light switch connector
24 Transmission mount upper
17 4x4 indicator switch connector
25 Transmission rubber
18 Transfer neutral switch connector
26 Transmission mount lower
19 Vehicle speed sensor connector
Transmission Removal/installation Note
Warning
• Remove the transmission carefully, holding it steady. If the transmission falls it could be damaged
or cause injury.
Caution
• When removing/installing the transmission, do not move it more than necessary so as to prevent
part interference with the body.
Note
• Two transmission jacks are necessary for the transmission removal/installation.
1. Remove the front differential mount rubber. (See

03-14A-2 FRONT DIFFERENTIAL REMOVAL!
INSTALLATION.)
MOUNT RUBBER
DBG511BWB019
2. Support the transfer side securely using one

transmission jack.
DBG511 BWB020
05-118-11
4. Support the transmission securely using the other
transmission jack.
5. When removing/installing the transmission,
secure the transmission using the transmission
jack attachment to prevent it from tilting to the left
or right.
Caution
• Do not allow the transmission jack to
interfere with the transmission mount
bracket bolts, otherwise the bolts could
be damaged.
DBG511 BWB021
6. Remove the first transmission jack.

7. Remove the transmission installation bolts.
8. Remove the transmission.
INSPECTION AFTER TRANSMISSION INSTALLATION [S15M-D]

dcf05110000OW09
Note
• Perform the following inspection only when the transmission has been overhauled.
1. Perform a road test and inspect the following items:

(1) No abnormal noise in each shift position.
(2) Smooth shift operation when shifting gears.
(3) No gear slipout after shifting gears.
(4) Back-up light switch operates correctly.
INSPECTION AFTER TRANSMISSION AND TRANSFER INSTALLATION [S15MX-D]

dcf05110000OW10
\.'
Note
• Perform the following inspection only when the transmission or transfer has been overhauled.
1. Perform a road test and inspect the following items:

(1) No abnormal noise in each shift position.
(2) Smooth shift operation when shifting gears.
(3) No gear slipout after shifting gears.
(4) Back-up light switch operates correctly.
05-118-12
OS-13 AUTOMATIC TRANSMISSION [SRSSS]

AUTOMATIC TRANSMISSION OUTPUT SHAFT SPEED (OSS)
LOCATION INDEX [5R55S] ...•..•.. 05-13-2 SENSOR REMOVAUINSTALLATION
MECHANICAL SYSTEM TEST [5R55S] ......•..•..••.......••... 05-13-33
[5R55S] .••.•..•.......•.....•••. 05-13-4 SOLENOID VALVE INSPECTION
ROAD TEST [5R55S] .......•..•.•.. 05-13-8 [5R55S] .•.••......•.•..•..•....•. 05-13-34
AIR PRESSURE TEST [5R55S] .••.... 05-13-10 SOLENOID BODY
LEAKAGE INSPECTION [5R55S] •.••. 05-13-11 REMOVAUINSTALLATION
AUTOMATIC TRANSMISSION FLUID ' [5R55S] ...••...........•.•...•... 05-13-35
(ATF) INSPECTION [5R55S] •........ 05-13-13 AT RELAY LOCATION [5R55S] ..•.•••. 05-13-38
AUTOMATIC TRANSMISSION FLUID AT RELAY INSPECTION [5R55S] .•...• 05-13-38
(AT F) REPLACEMENT [5R55S] ••.... 05-13-16 TCM INSPECTION [5R55S] ..........• 05-13-39
OlD OFF SWITCH INSPECTION TCM REMOVAUINSTALLATION
[5R55S] .••........•..•....•.•••. 05-13-19 [5R55S] •...••..•...............•. 05-13-44
DIGITAL TRANSMISSION RANGE AUTOMATIC TRANSMISSION
(TR) SENSOR INSPECTION REMOVAUINSTALLATION
[5R55S] ....•..•...•..•....•.•••. 05-13-20 [5R55S] •.......•..•.............. 05-13-45
DIGITAL TRANSMISSION RANGE TORQUE CONVERTER INSPECTION
(TR) SENSOR REMOVAUINSTALLATION [5R55S] .........••..............• 05-13-54
[5R55S] .••.•.•....•..•.......••. 05-13-22 TORQUE CONVERTER
DIGITAL TRANSMISSION RANGE REMOVAUINSTALLATION
(TR) SENSOR ADJUSTMENT [5R55S] ......•..••............... 05-13-55
[5R55S] .••.••.•.........•.•..••. 05-13-24 OIL SEAL (FLUID PUMP)
TRANSMISSION FLUID TEMPERATURE REPLACEMENT [5R55S] .•......•... 05-13-56
(TFT) SENSOR INSPECTION OIL SEAL (EXTENSION HOUSING)
[5R55S] . • • . . • . • . . . • . . • . . . . • . . • • . 05-13-26 REPLACEMENT [5R55S] .•..•..•.... 05-13-57
TURBINE SHAFT SPEED (TSS) EXTENSION HOUSING GASKET
SENSOR INSPECTION [5R55S] ••...• 05-13-28 REPLACEMENT [5R55S] .......•.... 05-13-58
TURBINE SHAFT SPEED (TSS) CONTROL VALVE BODY
SENSOR REMOVAUINSTALLATION REMOVAL [5R55S] •..........•..•. 05-13-61
[5R55S] ••••.••........•••....••. 05-13-29 CONTROL VALVE BODY
INTERMEDIATE SHAFT SPEED (ISS) INSTALLATION [5R55S] ••.•.......• 05-13-63
SENSOR INSPECTION [5R55S] ...... 05-13-30 OIL COOLER FLUSHING [5R55S] •.... 05-13-67
INTERMEDIATE SHAFT SPEED (ISS) OIL COOLER
SENSOR REMOVAUINSTALLATION REMOVAUINSTALLATION
[5R55S] •.......•.•....••.•...... 05-13-31 [5R55S] ......•..............••... 05~3-68
OUTPUT SHAFT SPEED (OSS) DRIVE PLATE
SENSOR INSPECTION [5R55S] ...... 05-13-32 REMOVAUINSTALLATION
[5R55S] •.....•.•....•..•..•.....• 05-13-71
05-13-1
AUTOMATIC TRANSMISSION LOCATION INDEX [SRSSS]
id0513c1249000
o 0 0 0 0 0
absggw00001006
05-13-2
1 OlD OFF switch 9 Automatic transmission fluid

(See 05-13-19 OlD OFF SWITCH INSPECTION (See 05-13-13 AUTOMATIC TRANSMISSION
[5R55S].) FLUID (ATF) INSPECTION [5R55S].)
2 Drive plate (See 05-13-16 AUTOMATIC TRANSMISSION
(See 05-13-71 DRIVE PLATE REMOVAU FLUID (ATF) REPLACEMENT [5R55S].)
INSTALLATION [5R55S].) 10 Transmission fluid temperature (TFT) sensor
3 Turbine shaft speed (TSS) sensor (See 05-13-26 TRANSMISSION FLUID
(See 05-13-28 TURBINE SHAFT SPEED (TSS) TEMPERATURE (TFT) SENSOR INSPECTION
SENSOR INSPECTION [5R55S].) [5R55S].)
(See 05-13-29 TURBINE SHAFT SPEED (TSS) 11 Solenoid valve
SENSOR REMOVAUINSTALLATION [5R55S].) (See 05-13-34 SOLENOID VALVE INSPECTION
4 Intermediate shaft speed (ISS) sensor [5R55S].)
(See 05-13-30 INTERMEDIATE SHAFT SPEED (See 05-13-35 SOLENOID BODY REMOVAU
(ISS) SENSOR INSPECTION [5R55S].) INSTALLATION [5R55S].)
(See 05-13-31 INTERMEDIATE SHAFT SPEED 12 Control valve body
(ISS) SENSOR REMOVAUINSTALLATION (See 05-13-10 AIR PRESSURE TEST [5R55S].)
[5R55S].) (See 05-13-61 CONTROL VALVE BODY REMOVAL
5 Output shaft speed (OSS) sensor [5R55S].)
(See 05-13-32 OUTPUT SHAFT SPEED (OSS) (See 05-13-63 CONTROL VALVE BODY
SENSOR INSPECTION [5R55S].) INSTALLATION [5R55S].)
(See 05-13-33 OUTPUT SHAFT SPEED (OSS) 13 TCM
SENSOR REMOVAUINSTALLATION [5R55S].) (See 05-13-39 TCM INSPECTION [5R55S].)
6 Digital transmission range (TR) sensor (See 05-13-44 TCM REMOVAUINSTALLATION
(See 05-13-20 DIGITAL TRANSMISSION RANGE [5R55S].)
(TR) SENSOR INSPECTION [5R55S].) 14 AT relay
(See 05-13-22 DIGITAL TRANSMISSION RANGE (See 05-13-38 AT RELAY LOCATION [5R55S].)
(TR) SENSOR REMOVAUINSTALLATION (See 05-13-38 AT RELAY INSPECTION [5R55S].)
[5R55S].) 15 Torque converter
(See 05-13-24 DIGITAL TRANSMISSION RANGE (See 05-13-54 TORQUE CONVERTER
(TR) SENSOR ADJUSTMENT [5R55S].) INSPECTION [5R55S].)
7 Automatic transmission (See 05-13-55 TORQUE CONVERTER REMOVAU
(See 05-13-4 MECHANICAL SYSTEM TEST INSTALLATION [5R55S].)
[5R55S].) 16 Oil seal (fluid pump)
(See 05-13-8 ROAD TEST [5R55S].) (See 05-13-56 OIL SEAL (FLUID PUMP)
(See 05-13-11 LEAKAGE INSPECTION [5R55S].) REPLACEMENT [5R55S].)
(See 05-13-45 AUTOMATIC TRANSMISSION
REMOVAUINSTALLATION [5R55S].) 17 Oil seal (extension housing)
(See 05-13-57 OIL SEAL (EXTENSION HOUSING)
8 Oil cooler REPLACEMENT [5R55S].)
(See 05-13-67 OIL COOLER FLUSHING [5R55S].)
(See 05-13-68 OIL COOLER REMOVAU 18 Extension housing gasket
INSTALLATION [5R55S].) (See 05-13-58 EXTENSION HOUSING GASKET
REPLACEMENT [5R55S].)
05-13-3
MECHANICAL SYSTEM TEST [5R55S]
id0513c1249100
Mechanical System Test Preparation
1. Engage the parking brake and use wheel chocks at the front and rear of the wheels.
2. Inspect the engine coolant level.
4. Inspect the ATF level. (See 05-13-13 AUTOMATIC TRANSMISSION FLUID (ATF) INSPECTION [5R55S].)
5. Inspect the idle speed.
Line Pressure Test (Pressure Control A, Pressure Control B)
Warning
• Removing the plug when the ATF is hot is dangerous. Hot ATF can discharge from the opening
and cause severe burns. Before removing the line pressure tap, allow the AT and ATF to cool.
Caution
• Perform the line pressure test before performing the stall test. If the line pressure is low at stall
speed, do not perform the stall test or further transmission damage will occur.
• Do not maintain WOT in any gear position for more than 5 s.
Note
• Certain sensor failures may cause high pressure control, Failure Mode Effect Management (FMEM)
actions. Be sure that the self-test and electrical repairs have been carried out or test results may be
incorrect.
• The line pressure tap is used to verify output pressure from pressure control A or pressure control B. Use
PC PIDs and take note which solenoid, pressure control A or pressure control B, is commanded higher.
Use the higher commanded PC x value when referencing the Line Pressure Charts A and B. The second
pressure tap is used to verify the output from the pressure control solenoid C.
Pressure control A, pressure control B

1. Remove the line pressure tap.
2. Connect the pressure gauge (SST: 307-004) to
the line pressure tap.
3. Connect the diagnostic scan tool and monitor the
PC A and PC B PIDs. Note which PID is
commanded higher. Use the higher commanded
PC x value when referencing the Line Pressure
Charts A and 8.
4. Start the engine and check the line pressure
reading from the gauge installed in Step 1. Refer
to the Line Pressure Chart for the correct shift
lever position.
absggw00001756
• If the line pressure is not within ranges given
in Line Charts A and B, refer to Line Pressure
Diagnosis Chart in this section for line pressure concern causes.
Line pressure (pressure control A, pressure

control B)
Line pressure (kPa {kgf/cm2, psi})
Position/range
Idle Stall
PIN 793 {B.09, 115} 793 {B.09, 115}
R 793 {B.09, 115} 2,13B {21.BO, 310}
D,3,2,1 793 {B.09, 115} 1,520 {15.47, 220}
05-13-4
kPa PSI
2,758 400 r---_,r---_.-----.-----r----~----._--_,----_.----_r----._----._----r_--~
- - - PND Line Commanded
2,413 350 - - - Min Line
- - - Max Line
2,068 300 t-----t-----t-----t-----~--~r_--~----~----~----~----_+----_+----_+----~
~
1,724 250
-- _--
, -
--
---,---,
::l
CJ) .............. ~ I....,..,.
CJ)
~ 1,379 200 _ - -' ~ - ' -'

-r------i
Il.
, -,-'
,
Q)
c
::J -,-'
-'...,.-----+-----+-----+-----1
--
150
1,035
---; - - -, ----I-- - '
-- --
....... .""..,.,
, , - , - '' - '
690 100 _ - :-J - I - - ' -:.,-----+-----+-----+-----t-----t-----r_--~
'
.............. I I .",....,
1-------
, , ,-,-' - '
--1-
345 50 -'.-----+-----t-----~----r_--~r_--~r_--~----~----_+----~
o I~
o
o 69 138 207 276 345 414 483 552 621 690 758 827 896 kPa
o 10 20 30 40 50 60 70 80 90 100 110 120 130 PSI
Commanded PCA or PCB

absggw00001757
kPa PSI
2,758 400
R Line Commanded
2,413 350 r--- - - Min Rev Line
- - - Max Rev Line
2,068 300
1,724 250 t-----t-----t-----~----r_--~r---~----~----~----~----_+----_+----_-~

_- I
~
::l .............. --; -,.,...,.,.
.............. ~
CJ)
CJ) . ..",.,.",..,.",....
~ 1,379 200 - -- - - ' ---+---i
Il. ..................... , ~.,..,.."
- ..................... ,
Q)
c . ..,.,.",.,
-
::J -,-'
1,035 150 t-----+-----t-----t-----~----I-_------; - -::..... , / - - , --_+----_+----_+-----+----...,
..................... , ,;.."""" - '
690 100 +-__~----_+--_ _ -:::: I _ ,;.. -'-_+----_+----_+----_+-----+-----+-----+-----l
.............. I . ..",..".
'------- I I . .",.",.,.".
-'
-'
345 50
0 0
o 69 138 207 276 345 414 483 552 621 690 758 827 896 kPa
o 10 20 30 40 50 60 70 80 90 100 110 120 130 PSI
Commanded PCA or PCB

f:bsggw00001758
5. Install the line pressure tap.
Tightening torque
10--15 N·m {102--152 kgf·cm, 89-132 in·lbf}
6. Go to the Pressure Control C Pressure Test in this section.

05-13-5
Pressure Control C
1. If not previously connected, install the scan tool.
2. Remove the line pressure tap.
3. Connect the pressure gauge (SST: 307-004) to
the line pressure tap.
4. Using the diagnostic scan tool, monitor the PC C
PID and note the commanded pressure.
5. Start the engine and check the PC C pressure.
• If the gauge reading does not match within ±
103 kPa {1.05 kgflcm 2 , 15 psi} of the PID
value displayed for the PC C, inspect the
pressure control solenoid C. (See 05-13-34
SOLENOID VALVE INSPECTION [5R55S].)
• If pressure control solenoid C operation is absggw00001759
normal, refer to the Line Pressure Diagnosis
Chart in this section for line pressure concern
causes.
Line pressure (pressure control C)
Line pressure (kPa {kgf/cm 2 , psi})
Position/range
Idle Stall
PIN 27 {O.28, 4} o {O, O}
R 793 {8.09, 115} 793 {8.09, 115}
D,3,2,1 . 27 {O.28, 4} o {O, O}
6. Install the line pressure tap.
Tightening torque
10-15 N·m {102-152 kgf·cm, 89-132 in·lbf}
Line pressure diagnosis chart

Test Results Possible Source
• Wiring harnesses
High at Idle-All Ranges • PC C boost valve
• Pressure control solenoid C
• Main regulator valve
• Low fluid level
• Fluid inlet filterlseal
• Control valve body
Low at Idle-All Ranges • Cross leaks
• Gaskets
• Pump
• Separator plate
• Forward Clutch
Low-All Forward Ranges • Main Control
• Overdrive brake servo
• Intermediate brake servo
Low in P position Only • Control valve body
• Separator plate
• Reverse servo piston, cover seal
• Reverse clutch
Low in R position Only • Overdrive brake servo
• Forward clutch
Low in N position Only • Overdrive brake servo
• Forward clutch
Low in D range • Overdrive brake servo
• Forward clutch
Low in D range Only (OlD OFF mode) • Overdrive brake servo
05-13-6
Test Results Possible Source
Low in 1 range • Forward clutch

Low in 2 range • Overdrive brake servo
• Forward clutch
Low in 3 range • Overdrive brake servo
• Forward clutch
Stall Speed Test
Warning
• Apply the parking brake firmly while performing each stall test. Failure to set the brakes can result
in death or severe injury.
Caution
• Perform the line pressure test before performing the stall test. If the line pressure is low at stall
speed, do not perform the stall test or further transmission damage will occur.
• The stall test should only be performed with the engine and transmission at normal operating
temperature.
Note
• The stall speed test inspects the operation of the following:
Torque converter clutch
Forward clutch
Low/reverse one-way clutch
Low one-way clutch component
Engine driveability concerns
Overdrive one-way clutch component
1. Connect a tachometer to the engine.
Caution
• Do not maintain WOT in any shift position for more than 5 s.
• If the engine rpm recorded by the tachometer exceeds the maximum specified rpm, release the
accelerator pedal immediately. Otherwise, clutch or band slippage could occur.
Note
• Prolonged use of this procedure may set DTC P0712 or P1783. After carrying out the Stall Speed Test,
run the OBD Test and clear DTCs from the memory.
2. Depress the accelerator pedal to the floor (WOT) in each shift position. Record the rpm reached in each shift
position.
Engine stall speed

Engine type rpm
WL-C 2,700
WE-C 2,900
05-13-7
3. After testing the D, 3, 2, 1 range and R position, shift the selector lever to the N position and run the engine at
1,000 rpm for 15 s to allow the torque converter to cool before testing the next gear position.
• If the stall speed is too high, refer to the stall speed diagnosis chart.
Stall speed diagnosis chart
Position/range Stall speeds high Stall speeds low
D, D (O/D OFF mode) and 1 • Overdrive one-way clutch

-
• Rear one-way clutch
D (O/D OFF mode), 2 and 1 • Forward clutch -

• Overdrive one-way clutch
D • Forward clutch
-
• General pressure concerns
• Converter one-way clutch or engine
D, D (O/D OFF mode), 2,1 and R • Forward clutch
driveability concerns
• High/reverse
R • High clutch -
• Low/reverse band/servo
2 • Intermediate band/servo -
1 • Intermediate band/servo -
4. If the stall speed is too low, inspect the idle speed.
• If the idle speed is normal, remove the torque converter and inspect the torque converter one-way clutch for
slippage.
ROAD TEST [5R55S]

id0513c1248900
Warning
• When performing a road test, be aware of other vehicles, people, and impediments to avoid an
accident.
Note
• Always drive the vehicle in a safe manner according to driving conditions and obey all traffic laws.
• When the legal speed limit must be exceeded, use a chassis dynamometer instead of performing a road
test.
Road Test Preparation

1. Inspect the engine coolant level.
3. Inspect the ATF level. (See 05-13-13 AUTOMATIC TRANSMISSION FLUID (ATF) INSPECTION [5R55S].)
4. Inspect the idle speed.
Shift Point Road Test
Note
• This test verifies that the shift control system is operating correctly.
1. Bring up the engine and transmission to normal operating temperature.

2. Shift the selector lever to the D range.
3. Apply minimum throttle and observe speeds at which up-shift occurs and the torque converter engages.
Caution
• Do not exceed posted speed limits when performing this test.
05-13--8
Shift speed (Reference) WL-C
Throttle position Gear position Vehicle speed (kmlh {mph})
5-4 33-35 {20-22}
Closed
4-1 17-19 {10-12}
1-2 17-19 {10-12}
Minimum monitor PIO minimum TP volt 2-3 21-24 {13-15}
1.25 . 3-4 28-30 {17-19}
38-40 {23-25}
4-5
1-2 42-45 {26-28}
2-3 60-62 {37-39}
Wide open
3-4 80-83 {49-52}
4-5 115-122 {71-76}
Shift speed (Reference) WE-C

Throttle position Gear position Vehicle speed (km/h {mph})
5-4 44-46 {27-29}
Closed
4-1 17-19 {10-12}
1-2 17-19 {10-12}
Minimum monitor PIO minimum TP volt 2-3 26-29 {16-18}
1.25 3-4 31-33 {19-21}
4-5 52-54 {32-34}
1-2 42-45 {26-28}
2-3 61-66 {38-41}
Wide open
3-4 84-91 {52-57}
4-5 107-119 {66-74}
4. Stop the vehicle.

5. Depress OlD OFF switch to activate D range and repeat Step 3.
6. The transmission will make all upshifts except 4-5, and the torque converter clutch application should occur
above 46 km/h {29 mph}.
7. Press the accelerator pedal to the floor, wide open throttle (WOT). The transmission should shift from 3GR to
2GR or 3GR to 1GR depending on vehicle speed, and the torque converter clutch should release.
8. With the vehicle speed above 48 km/h {30 mph}, move the transmission range selector lever from D range to 1
range and release the accelerator pedal. The transmission should immediately downshift to 3GR. When the
vehicle speed drops below 32 km/h {20 mph}, the transmission should downshift into 1st gear.
9. If the transmission fails to up-shift/down-shift or the torque converter does not apply and release, inspect
according to "SYMPTOM TROUBLESHOOTING". (See 05-03-5 SYMPTOM TROUBLESHOOTING ITEM
TABLE [5R55S].)
'05-13-9
AIR PRESSURE TEST [SRSSS]
id0513c1249500
Note
• A no-drive or erratic shift condition may be due to inoperative bands and clutches. To diagnose these
conditions a series of checks can be made by substituting air pressure for fluid to determine the location of
the damaged or obstructed component.
• Follow the procedure to determine the location of the inoperative clutch or band by substituting air
pressure into the various test plate passages.
• Use only dry, regulated air pressure, 276 kPa {2.8 kgflcm 2 , 40 psi} maximum.
1. Remove the control valve body. (See 05-13-61 CONTROL VALVE BODY REMOVAL [5R55S].)
2. Install the transmission test plate and gasket (SST: 307-433-01, 307-433-02, 307-433-03).
Tightening torque
10 N·m {102 kgf·m, 111.6-89 ft.lbf}
Note
• Do not apply air to the test plate vent hole.
3. Apply air to the appropriate clutch or servo port.

Refer to the Air Pressure Test Diagnostic Chart
for conditions, possible causes and actions.
1 Reverse servo
2 Intermediate servo
o
3 Overdrive servo o
4 Coast clutch o
5 Forward clutch
6 Direct clutch o
7 Reverse servo modulator
absggw00001755
4. After the testing is completed, remove the air test
plate and gasket (SST: 307-433-01,307-433-02,
307-433-03) and proceed with any repairs that are needed.
5. After the repairs are completed, install the control valve body. (See 05-13-63 CONTROL VALVE BODY
Air pressure test diagnostic chart
Condition Possible causes Actions
Concerns may not be in the
Dull thud heard or movement felt when Clutches, bands and fluid passages are transmission. Check the powertrain
air is applied and released normal. TCM, wiring harness and non-
transmission related components.
Disassemble the transmission, clean and
No drive Clutches and bands inoperative.
inspect to locate area of concern.
Clutches and bands inoperative due to Disassemble the transmission, clean and
Erratic shifts
incorrect pressures. inspect to locate area of concern.
Clutches, bands and fluid passages may Disassemble the transmission, clean and
No dull thud heard
be damaged or obstructed. inspect to locate area of concern.
Clutches, bands and fluid passages may Disassemble the transmission, clean and
No movement felt
be damaged or obstructed. inspect to locate area of concern.
Clutch seals or check ball may be Disassemble the transmission, clean and
Hissing sound heard
damaged or leaking. inspect to locate area of concern.
Seals and pistons may be damaged.
Servos do not operate Supply and release ports may be
inspect to locate area of concern.
obstructed. Spring may be broken.
Fluid passages in center support or inspect to locate area of concern.Check
Multiple clutches are applied
clutch cylinders may be obstructed. fluid passages in the center support for
obstructions.
05-13-10
LEAKAGE INSPECTION [5R55S]
id0513c1249600
Leak Check Test with a Black Light
Note
• Automatic Transmission/Power Steering Dye (specifically formulated for ATF) is used to detect a
transmission fluid leak.
1. Add Automatic Transmission/Power Steering Dye to the transmission fluid. Use one 30.0 mL {30.0 cc, 1 ft oz}
of dye solution for every 3.8 L {4.0 US qt, 3.3 Imp qt} of transmission fluid.
2. Start and run the engine until the transmission reaches its normal operating temperature.
3. Observe the back of the cylinder block and top of the torque converter housing for evidence of fluid leakage.
4. Raise the vehicle on a hoist.
5. Run the engine at fast idle, then at engine idle, occasionally shifting to the D range and R position to increase
pressure within the transmission.
6. Observe the front of the flexplate, back of the cylinder block (in as far as possible), inside the torque converter
housing and the entire case until fluid leakage is evident and the probable source of leakage can be detemined.
Caution
• Do not try to stop a fluid leak by increasing the torque beyond specifications. This may cause
damage to the transmission case threads.
External fluid leaks

Leak path Possible source
• Pan bolts not tightened to specification.
Leaks at the fluid pan-to-case • Case pan rail damaged.
• Pan gasket damaged.
• Cooler line(s), cooler line fitting(s) damaged.
• Cooler line fittings-to-case union damaged.
Fluid cooler lines or fittings leaking
• Case damage at case fitting.
• Fittings not tightened to specifications.
• Damaged or missing a-rings.
Fluid cooler line nut-to-case fittings leaking
• Fittings not tightened to specifications.
• Fluid cooler damage.
Leaks at the fluid cooler
• Fitting(s) damaged or not tightened to specifications.
• Damaged or missing a-rings.
Leaks at the external sensors
• Screw not tightened to specifications.
Leaks at the manual control lever seal • Damaged or missing lever seal.
• Install a new solenoid body wiring harness connector 0-
Leaks at the solenoid body harness connector ring seal. Either on the wiring harness end or the solenoid
body.
• For possible sources refer to Fluid Leakage In Torque
Fluid leakage in the torque converter area
Converter Area Chart.
05-13-11
Fluid Leakage in Torque Converter Area
• In diagnosing and correcting fluid leaks in the front pump support and gear and torque converter area, use the
following procedures to locate the exact cause of the leakage.
• Leakage at the front of the transmission, as evidenced by fluid around the torque converter housing, may have
several sources.
• By careful observation it is possible, in many instances, to pinpoint the source of leak before removing the
transmission from the vehicle.
• The paths which the fluid takes to reach the bottom of the torque converter housing are shown in the
illustration.
Leak path Symptom Possible source
Leak at front of
1,2 and 4 Pump lip seal
transmission
Leak at front of Converter hub
1,2 and 4
transmission weld
Leak at front of External pump
1,2 and 4
transmission seal (large)
Leak at front of Pump-to-case
1,2 and 4
transmission screws
Leak at front of
1,2 and 4 Pump gasket
transmission
Leak at front of Torque converter
3
transmission seal weld
Leak at front of Torque converter
3
transmission stud
Leak at front of Engine oil leak-
5
transmission rear main seal
Leak at front of Engine valve
5
transmission cover
Leak at front of
5 Oil galley
transmission
Leak at front of Engine oil
5
transmission pressure sensor absggw00001754
Leak between
6 engine and Venting
transmission case
05-13-12
AUTOMATIC TRANSMISSION FLUID (ATF) INSPECTION [5R55S]
id0513c1251100
Automatic Transmission Fluid (AT F) Condition Inspection

1. Hold the larger drain plug with a wrench and r-----------------------,
remove the small (center) fluid level indicating
plug.
2. Check the ATF level.
3. Observe the color and the odor of the ATF.
• Under normal circumstances the color should
be dark reddish, not brown or black.
4. Allow the ATF to drip onto a facial tissue and
examine the stain.
• If evidence of solid material is found, the fluid
pan should be removed for further inspection.
• If ATF contamination or transmission failure is
absggw00001022
confirmed by the sediment in the bottom of
the fluid pan, the transmission must be
disassembled and completely cleaned.
5. Install the small (center) fluid level indicating plug.
Tightening torque
Automatic Transmission Fluid (ATF) Level Inspection

1. Connect the M-MDS to the vehicle DLC-2 16-pin
connector.
2. Verify the ATF temperature using the PID/data
monitor "TFT".
3. Warm up the automatic transmission until the ATF
temperature is 27-49 °C {80-120 OF}.
4. Move the range selector lever slowly through
each gear, stopping in each position and allowing
the transmission to engage.
5. Place the selector lever in the P position.
6. Hold the larger drain plug with a wrench and

plug.
absggw00001022
7. Install the SST into the pan.
Note
• Prior to filling the SST with clean ATF, make
sure that the canister is clean.
307-437
(49 UN30 7437)
arnffwOOOO 1950
05-13-13
8. Fill the SST with clean ATF.
9. Hang the SST under the vehicle. Position it

upright and close to the transmission.
10. Connect the SST.

• Connect the open end of the fluid hose from
the SST (307-D465) to the SST (307-437) at
the bottom of the fluid pan.
11. Apply a maxjmum of 206.85 kPa {2.11 kgf/cm 2 ,

30.0 pis} to the open end of the vacuum/pressure
hose from the rubber tip air nozzle. Fluid will
immediately start flowing out of the SST into the
fluid pan.
12. Add 0.5 L {0.5 US qt, 0.4 Imp qt} of ATF into the
fluid pan. Stop the process by releasing the air
pressure and removing the air nozzle from the
end of the hose. 206.85 kPa
13. Inspect the ATF level in the SST. {2.11 kgf/m 2 ,
30.0 pis}
• If the fluid drains back into the canister, the
transmission is full. arnffw00001954
• If no fluid drains back, more fluid will need to
be added. Repeat Steps 11 and 12.
05-13-14
14. Once the transmission is full, place a hand
vacuum pump on the open end of the vacuum/
pressure hose on the SST and apply vacuum to
the system. This will pull out any extra fluid
trapped in the system and direct it into the
container.
15. Make sure that the ATF temperature is between
27-49 °C {80-120 OF}.
16. Allow the ATF to drain.

• When the ATF comes out as a thin stream or
drip, the ATF is at the correct level.
absggw00001029
Tightening torque
18. Check the operation of the transmission by

moving the selector lever slowly through each
gear, stopping in each position and allowing the
transmission to engage.
ATF @ ° @ °
Type: Mercon® V
05-13-15
AUTOMATIC TRANSMISSION FLUID (ATF) REPLACEMENT [SRSSS]
id0513c1251200 .
Draining
1. Place the selector lever in the P position.
2. Remove the drain plug (large plug) and allow the
ATF to drain.
absggw00001030
Refill
1. Install the drain plug (large plug).
Tightening torque
24-28 N·m {2.S-2.8 kgf·m, 18-20 ft.lbf}
absggw00001030
2. Hold the larger drain plug with a wrench and

plug.
o(
I~
))QL2J
o~ ~l'
tJ @
~~L~v
0 @ 0 0
absggw00001022
3. Install the SST into the pan.
Note
• Prior to filling the SST with clean ATF, make
sure that the canister is clean.
arnffw00001950
05-13-16
4. Fill the SST with clean ATF.
5. Hang the SST under the vehicle. Position it

upright and close to the transmission.
6. Connect the SST.

• Connect the open end of the fluid hose from
the SST (307-D465) to the SST (307-437) at
the bottom of the fluid pan.
7. Apply a maximum of 206.85 kPa {2.11 kgflcm 2 ,

30.0 pis} to the open end of the vacuum/pressure
hose from the rubber tip air nozzle. Fluid will
immediately start flowing out of the SST into the
fluid pan.
8. Add 1.89-2.83 L {2.00-2.99 US qt, 1.67-2.49
imp qt} of ATF into the fluid pan. Stop the
process by releasing the air pressure and
removing the air nozzle from the end of the hose. 206.85 kPa
{2.11 kgflm 2 ,
30.0 pis}
arnffw00001954
9. Connect the M-MDS to the vehicle DLC-2 16-pin

connector.
10. Verify the ATF temperature using the PID/data
monitor "TFT".
11. Warm up the automatic transmission until the ATF
temperature is 27-49 °C {80-120 OF}.
12. Inspect the ATF level in the SST.
• If the fluid drains back into the canister, the
transmission is full.
• If no fluid drains back, more fluid will need to
be added. Repeat Steps 7 and 8.
absggw00000987
05-13-17
13. Once the transmission is full, place a hand
vacuum pump on the open end of the vacuum/
pressure hose on the SST and apply vacuum to
the system. This will pull out any extra fluid
trapped in the system and direct it into the
container.
14. Allow the ATF to drain .

• When the ATF comes out as a thin stream or
drip, the ATF is at the correct level.
absggw00001029
I~
r?l'
Tightening torque
o( ))Q~
o~
ATF
Type: Mercon® V
Capacity (approx. quantity): 9.93 L {1 0.49 US
qt, 8.74 Imp qt} til~L--,-,v
@ 0 @ 0 0
absggw00001022
05-13-18
010 OFF SWITCH INSPECTION [SRSSS]
id0513c1254200
Operation Inspection
2. Verify that the OlD OFF indicator light is not illuminated. Press the OlD OFF switch and verify that the OlD OFF
indicator light illuminates.
• If there is any malfunction, inspect the terminal voltage of the OlD OFF switch. (See 05-13-19 Voltage
Inspection.)
Voltage Inspection
2. Measure the voltage at the OlD OFF switch
connector.
• If there is any malfunction, inspect for
continuity at the OlD OFF switch. (See 05-13-
19 Continuity Inspection.)
Connector terminal
Position
C D
OFF (Normal) (V) B+ 0
ON (Depressed) (V) 0 0
absggw00001008
1. Disconnect the OlD OFF switch connector.
table.
• If the switch is normal, inspect the wiring
harness. (OlD OFF switch-TCM, OlD OFF
switch-Body ground)
• If there is any malfunction, replace the
selector lever component. (See 05-14-4
SELECTOR LEVER REMOVAU
INSTALLATION.)
0-0 : Continuity
Terminal
Switch
C D
ON (Normal)
OFF (Depressed) () -0
absggw00001858
05-13-19
DIGITAL TRANSMISSION RANGE (TR) SENSOR INSPECTION [5R55S]
id0513c1254700
Operating Inspection
1. Verify that the starter operates only when the engine switch is turned to the START position with the selector
lever in the P or N position.
• If there is any malfunction, adjust the digital TR sensor. (See 05-13-24 DIGITAL TRANSMISSION RANGE
(TR) SENSOR ADJUSTMENT [5R55S].)
2. Verify that the back-up lights illuminate when shifted to the R position with the engine switch at the ON position.
• If there is any malfunction, adjust the digital TR sensor. (See 05-13-24 DIGITAL TRANSMISSION RANGE
(TR) SENSOR ADJUSTMENT [5R55S].)
3. Verify that the positions of the selector lever and
the indicator are aligned.
• If there is any malfunction, adjust the digital
TR sensor. (See 05-13-24 DIGITAL
TRANSMISSION RANGE (TR) SENSOR
ADJUSTMENT [5R55S].)
absggw00001014
Caution

2. Remove the digital TR sensor insulator.
DIGITAL TR
SENSOR
INSULATOR
absggw00001811
3. Disconnect the digital TR sensor connector.
absggw00001812
05-13-20
table.
ADJUSTMENT [5R55SJ.)
0-0 : Continuity
Terminal
Selector
position
A B C D E F G H I J L
P
0 -0 absggw00001017
R
0 -0
N
0 -0 0 -0
D
,......
3 0 0
,......
2 0 '-' -0
1 ,......
Q '-' -0
absggw00001018
5. Reinspect for continuity at digital TR sensor.

• If there is any malfunction, replace the digital TR sensor. (See 05-13-22 DIGITAL TRANSMISSION RANGE
(TR) SENSOR REMOVAUINSTALLATION [5R55SJ.)
6. Connect the digital TR sensor connector.
7. Install the digital TR sensor insulator.
Tightening torque
7.S-10.7 N·m {SO-10S kgf.cm, 69.1-94.7
in.lbf}
DIGITAL TR
SENSOR
INSULATOR
absggw00001811
05-13-21
DIGITAL TRANSMISSION RANGE (TR) SENSOR REMOVAUINSTALLATION [5R55S]
id0513c1254800
Caution

DIGITAL TR
SENSOR
INSULATOR
absggw00001811

4. Remove the selector cable.
absggw00001813
5~ Set the adjustable wrench as shown in the figure

to hold the manual shaft lever.
6. Remove the manual shaft nut.
MANUAL SHAFT
LEVER
absggw00001032
8. Remove the digital TR sensor.
DIGITAL TR SENSOR
absggw00001814
/ .
05-13-22
9. Rotate the manual shaft to the torque converter
housing side fully and return two notches to set MANUAL SHAFT
the N position.
10. Install the digital TR sensor and loosely install the
screws.
TORQUE
CONVERTER
Caution HOUSING SIDE
• Tightening one screw before tightening
the other may cause the digital TR sensor p
to bind or become damaged.
Note
absggw00001034
11. Using the SST, align the digital TR sensor and

tighten the screws in an alternating sequence.
Tightening torque
6.5-9.5 N·m {67- 96 kgf·cm, 58-84 in.lbf}
Caution
• Do not use an impact wrench. Hold the
manual shaft lever when tightening the
manual shaft nut, otherwise the
transmission may be damaged.
J
12. Install the manual shaft lever.
Tightening torque
61-74 N·m {6.3- 7.5 kgf·m, 45-54 ft.lbf}
13. Shift the selector lever to P position.

14. Turn the manual shaft lever to P position.
MANUAL SHAFT
LEVER
15. Install the selector cable.

DIGITAL TR SENSOR CD:::\ ) SELECTOR CABLE

CONNECTOR ~
.... 1
absggw00001813
Tightening torque
7.8-10.7 N·m {80-108 kgf·cm, 69.1-94.7
in·lbf}

19. Inspect digital TR sensor operation. (See 05-13-
20 DIGITAL TRANSMISSION RANGE (TR) DIGITAL TR
SENSOR INSPECTION [5R55S].) SENSOR
INSULATOR
absggw00001811
05-13-23
DIGITAL TRANSMISSION RANGE (TR) SENSOR ADJUSTMENT [5R55S]
id0513c1254900
Caution

absggw00001811

4. Remove the selector cable.
5. Rotate the manual shaft to the N position.
Caution
manual shaft lever when removing the
DIGITAL TR SENSOR CCb
CONNECTOR c.SJ
'-
absggw00001813
6. Set the adjustable wrench as shown in the figure

7. Remove the manual shaft nut.
absggw00001032
9. Loosen the digital TR sensor mounting bolts.
Caution
• Tightening one screw before tightening
the other may cause the digital TR sensor
to bind or become damaged.
Note
DIGITAL TR SENSOR
absggw00001814
05-13-24
10. Using the SST, align the digital TR sensor and
tighten the screws in an alternating sequence.
-~
u I ) ~/
Tightening torque
6.5-9.5 N·m {67- 96 kgf·cm, 58-84 in.lbf}
J
absggw00001035
11. Inspect for continuity between digital TR sensor
terminals A, E and I.
Caution
manual shaft lever when tightening the
absggw00001017
12. Install the manual shaft lever.
Tightening torque
61-74 N·m {6.3-7.5 kgf·m, 45-54 ft.lbf}
13. Set the adjustable wrench as shown in the figure

14. Tighten the manual shaft nut using a torque
wrench.
MANUAL SHAFT
Tightening torque LEVER
14-18 N·m {1.5-1.8 kgf·m, 11-13 ft.lbf}
15. Shift the selector lever to P position.

16. Turn the manual shaft lever to P position.
17. Install the selector cable.
DIGITAL TR SENSOR a:::J::\ ) SELECTOR CABLE

CONNECTOR '- ~ 1
absggw00001813
Tightening torque
7.8-10.7 N·m {80-108 kgf·cm, 69.1-94.7
in.lbf} -

21. Inspect digital TR sensor operation. (See 05-13-
20 DIGITAL TRANSMISSION RANGE (TR) DIGITAL TR
SENSOR INSPECTION [5R55S].) SENSOR
INSULATOR
absggw00001811
-05-13-25
TRANSMISSION FLUID TEMPERATURE (TFT) SENSOR INSPECTION [5R55S]
id0513c1710300
Caution
On-Vehicle Inspection
3. Remove the CKP sensor insulator.
4. Remove the insulator bracket.
5. Disconnect the AT connector.
absggw00001183
6. Measure resistance between the AT terminals K

and L.
• If there is any malfunction, perform the off-
vehicle inspection for TFT sensor. (See 05-
13-27 Off-Vehicle Inspection.)
Transmission fluid temperature (TFT) sensor

ATF temperature (OC ("F}) Resistance (kilohm)
-40--20 {-40--4} 284-967
-19--1 {-3-30} 100-284
0-20 {32-68} 37-100
21-40 {70-104} 16-37 absggw00001184
41-70 {106-158} 5-16

71-90 {160-194} 2.7-5
91-110 {196-230} 1.5-2.7
111-130 {232-266} 0.8-1.5
131-150 {268-302} 0.54-0.8
7. Connect the AT connector.

8. Remove the insulator bracket. (See 05-13-45 AUTOMATIC TRANSMISSION REMOVAUINSTALLATION
[5R55S].)
9. Remove the CKP sensor insulator. (See 05-13-45 AUTOMATIC TRANSMISSION REMOVAL/INSTALLATION
[5R55S].)
10. Remove the digital TR sensor insulator. (See 05-13-45 AUTOMATIC TRANSMISSION REMOVAU
05-13-26
Off-Vehicle Inspection
Warning
• A hot the transmission and ATF can cause severe burns. Turn off the engine and wait until they are
cool before replacing ATF.
1. Remove the solenoid body. (See 05-13-35 SOLENOID BODY REMOVAUINSTALLATION [5R55S].)
2. Place the solenoid body and a thermometer in ATF as shown in the figure, and heat the ATF gradually.
3. Measure the resistance between the solenoid
body terminals K and L.
solenoid body. (See 05-13-35 SOLENOID
BODY REMOVAUINSTALLATION [5R55S].)

ATF temperature eC ("F}) Resistance (kilohm)
-40--20 {-40--4} 284--967
-19--1 {-3-30} 100-284
0-20 {32-68} 37-100
21-40 {70-104} 16-37 absggw00001185
41-70 {106-158} 5-16

71-90 {160-194} 2.7-5
91-110 {196-230} 1.5-2.7
111-130 {232-266} 0.8-1.5
131-150 {268-302} 0.54--0.8
4. Install the solenoid body. (See 05-13-35 SOLENOID BODY REMOVAUINSTALLATION [5R55S].)
05-13-27
TURBINE SHAFT SPEED (TSS) SENSOR INSPECTION [5R55S]
id0513c1252900
Caution

2. Remove the oxidation catalytic converter.
6. Disconnect the TSS sensor connector.
Caution
• Do not apply a shock in the TSS sensor.
absggw00001186
7. Measure the resistance between the TSS sensor
{I
terminals.
• If there is any malfunction, replace the TSS
sensor. (See 05-13-29 TURBINE SHAFT
SPEED (TSS) SENSOR REMOVAU
TSS sensor resistance
I~~I
Resistance (ohm) Temperature (OC eF})
226-390 -20 {4}
325-485 21 {70}
492-738 150 {302} absggw00001189
. 8. Connect the TSS sensor connector.

9. Install the crossmember and transmission mount rubber. (See 05-13-45 AUTOMATIC TRANSMISSION
10. Install the propeller shaft. (See 03-15-2 PROPELLER SHAFT REMOVAUINSTALLATION [5AT].)
11. Install the oxidation catalytic converter.
05-13-28
TURBINE SHAFT SPEED (TSS) SENSOR REMOVAUINSTALLATION [5R55S]
id0513c1253000
Caution
• Do not damage the TSS sensor.

6. Disconnect the TSS sensor connector.
7. Remove the TSS sensor.
Note
• Inspect O-ring for damage. Install new 0-
ring if damaged. Lubricate the O-ring with
ring.
8. Install the TSS sensor.
Tightening torque
8-12 N·m {82-122 kgf·cm, 71-106 in.lbf}
absggw00001186
9. Connect the TSS sensor connector.

05-13-29
INTERMEDIATE SHAFT SPEED (ISS) SENSOR INSPECTION [5R55S]
id0513c1253400
Caution

3. Remove the propeller shaft. (See 03-15-2 PROPELLER SHAFT REMOVAL/INSTALLATION [5AT].)
REMOVAL/INSTALLATION [5R55S].)
6. Disconnect the ISS sensor connector.
Caution
• Do not apply a shock in the ISS sensor.
absggw00001187
7. Measure the resistance between the ISS sensor
I)
terminals.
• If there is any malfunction, replace the ISS
sensor. (See 05-13-31 INTERMEDIATE
SHAFT SPEED (ISS) SENSOR REMOVAL/
ISS sensor resistance
I~~I
Resistance (ohm) Temperature (OC eF})
226-390 -20 {4}
325-485 21 {70}
492-738 150 {302} absggw00001189
8. Connect the ISS sensor connector.

10. Install the propeller shaft. (See 03-15-2 PROPELLER SHAFT REMOVAL/INSTALLATION [5AT].)
05-13-30
INTERMEDIATE SHAFT SPEED (ISS) SENSOR REMOVAUINSTALLATION [SRSSS]
id0513c1253500
Caution
• Do not damage the ISS sensor.

3. Remove the propeller shaft. (See 03-15-2 PROPELLER SHAFT REMOVAL/INSTALLATION [SAT].)
6. Disconnect the ISS sensor connector.
7. Remove the ISS sensor.
Note
Tt---rc:"......::,,--_ISS SENSOR
• Inspect O-ring for damage. Install new 0- CONNECTOR
ring.
8. Install the ISS sensor.
Tightening torque
8-12 N·m {82-122 kgf.cm, 71-106 in.lbf}
absggw00001187
9. Connect the ISS sensor connector.

11. Install the propeller shaft. (See 03-15-2 PROPELLER SHAFT REMOVAL/INSTALLATION [5AT].)
05-13-31
OUTPUT SHAFT SPEED (OSS) SENSOR INSPECTION [5R55S]
id0513c1254000
Caution

6. Disconnect the OSS sensor connector.
I
Caution OSS SENSOR ~ 'J/ OSS SENSOR
• Do not apply a shock in the OSS sensor. CONNECTOR ~
~-~
~
h ...........
--"-~
.--:;:::::::; I
~~
absggw00001188
7. Measure the resistance between the OSS sensor

terminals.
• If there is any malfunction, replace the OSS
sensor. (See 05-13-33 OUTPUT SHAFT
SPEED (OSS) SENSOR REMOVAU
OSS sensor resistance

Resistance (ohm) Temperature (Oe eF})
226-390 -20 {4}
325-485 21 {70}
492-738 150 {302} absggw00001189
8. Connect the OSS sensor connector.

05-13-32
OUTPUT SHAFT SPEED (OSS) SENSOR REMOVAUINSTALLATION [SRSSS]
id0513c1254100
Caution
• Do not damage the OSS sensor.
,1.Disconnect the negative battery cable.

2.Remove the oxidation catalytic converter.
3.Remove the propeller shaft. (See 03-15-2 PROPELLER SHAFT REMOVAUINSTALLATION [5AT].)
4.Remove the crossmember and transmission mount rubber. (See 05-13-45 AUTOMATIC TRANSMISSION
6. Disconnect the OSS sensor connector.
7. Remove the OSS sensor.
Note OSS SENSOR

• Inspect O-ring for damage. Install new 0-
ring.
8. Install the OSS sensor.
Tightening torque
12-16 N·m {123-163 kgf·cm, 107-141
absggw00001188
in.lbf}
9. Connect the OSS sensor connector.

05-13-33
SOLENOID VALVE INSPECTION [5R55S]
id0513c1253200
Caution

absggw00001183
6. Measure the resistance between the following

terminals.
• If there is any malfunction, inspect the coupler
component.
• If the coupler component is normal, replace
the solenoid body. (See 05-13-35 SOLENOID
BODY REMOVAUINSTALLATION [5R55S].)
Solenoid valve resistance)

Resistance
Terminals Solenoid valve
(ohm)
D-I Shift solenoid A 16-45 absggw00001184
F-I Shift solenoid 8 16-45
8-1 Shift solenoid e 16-45
E-I Shift solenoid D 16-45
Pressure control
0-1 3.3-7.5
solenoid A
Pressure control
M-I 3.3-7.5
solenoid 8
Pressure control
G-I
solenoid e
3.3-7.5
H-I
Tee control 9-16
solenoid
7. Connect the AT connector.

8. Remove the insulator bracket. (See 05-13-45 AUTOMATIC TRANSMISSION REMOVAUINSTALLATION
[5R55S].)
9. Remove the CKP sensor insulator. (See 05-13-45 AUTOMATIC TRANSMISSION REMOVAUINSTALLATION
[5R55S].)
10. Remove the digital TR sensor insulator. (See 05-13-45 AUTOMATIC TRANSMISSION REMOVAL/
( .
05-13-34
SOLENOID BODY REMOVAL/INSTALLATION [5R55S]
id0513c1254400
On-Vehicle Removal
Warning
• A hot transmission and ATF can cause severe burns. Turn off the engine and wait until they are
Caution
• Clean the transmission exterior thoroughly with a stream cleaner or cleaning solvents before
removal.

2. Drain the ATF. (See 05-13-16 AUTOMATIC TRANSMISSION FLUID (ATF) REPLACEMENT [5R55S].)
Note
reusable. Clean and inspect the gasket for
damage. If not damaged, the gasket should
be reused.
absggw00001183
7. Remove the screws, transmission fluid pan and

gasket.

Caution
pins.
b5r5za00000015
05-13-35
b5r5za00000018
On-Vehicle Installation
Caution
and not damaged. If damaged,
b5r5za00000272

sequence shown.
Tightening torque
7-9 N·m {72-91 kgf.cm, 62-79 in·lbf}
Caution
damaged.
b5r5za00000273

fluid filter.
Tightening torque
9-11 N·m {92-112 kgf·cm, 80-97 in·lbf}
Note
b5r5za00000275
05-13-36
4. Install the transmission fluid pan gasket on the
pan.
Note
reusable, clean and inspect for damage. If GASKET
absggw00001562
5. Install the transmission fluid pump and gasket,

6. Tighten the bolts in a crisscross sequence.
Tightening torque
9.5-11.5 N·m {97-117 kgf·cm, 85-101
in.lbf}
Caution
• Damage will occur to the solenoid body
component if the screw is tightened
above specification.
7. Install and lubricate new O-rings on the AT

connector and connect the connector.
Tightening torque
Note
• Clean the area around connector to prevent
contamination of the AT connector.
• Use petroleum jelly to lubricate the O-rings
to aid in the installation process.
8. Remove the insulator bracket. (See 05-13-45

AUTOMATIC TRANSMISSION REMOVAL/
9. Remove the CKP sensor insulator. (See 05-13-45 AUTOMATIC TRANSMISSION REMOVAL/INSTALLATION
[5R55S].)
10. Remove the digital TR sensor insulator. (See 05-13-45 AUTOMATIC TRANSMISSION REMOVAL!
12. Add ATF and, with the engine idling, inspect the ATF level and for leakage. (See 05-13-13 AUTOMATIC
TRANSMISSION FLUID (ATF) INSPECTION [5R55S].)
13. Perform the mechanical system test. (See 05-13-4 MECHANICAL SYSTEM TEST [5R55S].)
14. Perform the road test. (See 05-13-8 ROAD TEST [5R55S].)
05-13-37
AT RELAY LOCATION [5R55S]
id0513c1254500
%.al~~""';--'---AT RELAY
absggw00001809
AT RELAY INSPECTION [5R55S]

id0513c1254600

2. Remove the AT relay.
3. Verify the continuity between the relay terminals.
relay.
0-0 : Continuity
Terminal
Step
A E C D
1 0 0
2 B+ GND 0 0
acxuuw00002119
acxuuw00002118
05-13-38
TCM INSPECTION [SRSSS]
id0513c1250700
Terminal Voltage/Resistance Table (Reference)
,.--
A E I M Q U Y AC AG AK AO AS AW BA BE BI BM BQ BU BY CC CG
It
-,--
B F J N R V Z AD AH AL AP AT AX BB BF BJ BN BR BV BZ CD CH -CKCL -CNCO
C G K 0 S W AA AE AI AM AQ AU AY BC BG BK BO BS ~W CA CE CI r-- -
CM CP
--- D H L P T X AB AF AJ AN AR AV AZ BD BH BL BP BT BX CB CF CJ '---
absggw00001190
Voltage!
Terminal Signal Connected to Test Condition. Action
Resistance
• Inspect the TCC control
solenoid
Inspect resistance between TCM (See 05-13-34
TCC control TCC control
A terminals A and CK (wiring harness- 9-16 ohm SOLENOID VALVE
solenoid control solenoid
side). INSPECTION [5R55S])
• Inspect the related
wiring harness
• Inspect the shift
solenoid A
Shift solenoid A
B Shift solenoid A terminals Band CK (wiring harness- 16-45 ohm SOLENOID VALVE
control
wiring harness
solenoid B
Shift solenoid B
C Shift solenoid B terminals C and CK (wiring harness- 16-45 ohm SOLENOID VALVE
control
wiring harness
solenoid 0
Shift solenoid 0
0 Shift solenoid 0 terminals 0 and CK (wiring harness- 16-45 ohm SOLENOID VALVE
control
wiring harness
Engine switch ON B+ • Inspect the instrument
OlD OFF Instrument cluster
E
indicator output cluster Engine switch OFF Below 1.0 V • Inspect the related
wiring harness
solenoid C
Shift solenoid C
F Shift solenoid C terminals F and CK (wiring harness- 16-45 ohm SOLENOID VALVE
control
wiring harness
Selector
Inspect continuity between TCM and
G
position Instrument
instrument cluster (wiring harness- Continuity • Inspect the related
indicator signal cluster wiring harness
side).
3
H - - - - -
05-13-39
Voltage!
Terminal Signal Connected to Test Condition Action
Resistance
• Inspect the pressure
control solenoid A
Pressure Pressure Inspect resistance between TCM (See 05-13-34
3.3-7.5
I control solenoid control solenoid terminals I and CK (wiring harness- SOLENOID VALVE
ohm
A control A side). INSPECTION [5R55S])
wiring harness
control solenoid B
3.3-7.5
J control solenoid control solenoid terminals J and CK (wiring harness- SOLENOID VALVE
ohm
B control B side). INSPECTION [5R55S])
wiring harness
Selector
K
position Instrument
side).
1
L - - - - -
control solenoid C
3.3-7.5
M control solenoid control solenoid terminals M and CK (wiring harness- SOLENOID VALVE
ohm
C control C side). INSPECTION [5R55S])
wiring harness
4x4 HI indicator Instrument cluster
N
output cluster Engine switch OFF Below 1.0 V • Inspect the related
wiring harness
0 - - - - -
P - - - - -
Selector
Q
position Instrument
side).
2
4x4 LO Instrument cluster
R
indicator output cluster Engine switch OFF Below 1.0 V • Inspect the related
wiring harness
S - - - - -
T - - - - -
U
Vehicle speed Instrument
output cluster wiring harness
side).
V - - - - -
W - - - - -
X - - - - -
y - - - - -
Z - - - - -
AA - - - - -
AB - - - - -
AC - - - - -
• Inspect the OSS sensor
(See 05-13-32
OUTPUT SHAFT
Inspect resistance between TCM
Output shaft 325-485 SPEED (OSS)
AD OSS sensor terminals AD and AG (wiring I
speed (+) ohm SENSOR INSPECTION
harness-side) .
[5R55S])
wiring harness
AE - - - - -
AF - - - - -
05-13-40
Voltage!
Resistance
• Inspect the OSS sensor
(See 05-13-32
OUTPUT SHAFT
Output shaft 325-485 SPEED (OSS)
AG OSS sensor terminals AD and AG (wiring
speed (-) ohm SENSOR INSPECTION
harness-side) .
[5R55SJ)
wiring harness
• Inspect the TSS sensor
(See 05-13-28
TURBINE SHAFT
Turbine shaft 325-485 SPEED (TSS)
AH TSS sensor terminals AH and AP (wiring
speed (-) ohm SENSOR INSPECTION
harness-side).
[5R55SJ)
wiring harness
AI
AJ
AK System GND GND Under any condition Continuity • Inspect the related
wiring harness
AL
• Inspect the ISS sensor
(See 05-13-30
INTERMEDIATE
Intermediate 325-485 SHAFT SPEED (ISS)
AM ISS sensor terminals AM and AS (wiring
shaft speed (-) ohm SENSOR INSPECTION
harness-side) .
[5R55SJ)
wiring harness
AN
AO System GND GND Under any condition Continuity • Inspect the related
wiring harness
• Inspect the TSS sensor
(See 05-13-28
TURBINE SHAFT
Turbine shaft 325-485 SPEED (TSS)
AP TSS sensor terminals AH and AP (wiring
speed (+) ohm SENSOR INSPECTION
harness-side) .
[5R55SJ)
wiring harness
AQ
AR
• Inspect the ISS sensor
(See 05-13-30
INTERMEDIATE
Intermediate 325-485 SHAFT SPEED (ISS)
AS ISS sensor terminals AM and AS (wiring
shaft speed (+) ohm SENSOR INSPECTION
harness-side).
[5R55SJ)
wiring harness
AT
AU
AV
AW
P position, 1,2
Continuity • Inspect the Digital TR
and 3 range sensor
Inspect continuity
(See 05-13-20 DIGITAL
between TCM
Digital TR TRANSMISSION
( AX TR3A signal
sensor
terminals AX and
Not RANGE (TR) SENSOR
BH (wiring Other
continuity INSPECTION [5R55SJ)
harness-side).
wiring harness
05-13-41
Voltage!
Resistance
ATF
temperature 284-967
-40--20°C kilohm
{-4Q--4 OF}
ATF
temperature 100-284
-19--1 °C kilohm
{-3-30 OF}
ATF
temperature 37-100
0-20°C kilohm
{32-68 OF}
ATF
temperature 16-37
21-40°C kilohm
{70-104 OF}
• Inspect the TFT sensor
(See 05-13-26
Inspect resistance
ATF TRANSMISSION
between TCM
ATF temperature 5-16 FLUID TEMPERATURE
AY TFT sensor terminals AY and
temperature 41-70°C kilohm (TFT) SENSOR
BH (wiring
{106-158 OF} INSPECTION [5R55S])
harness-side).
ATF • Inspect the related
temperature 2.7-5 wiring harness
71-90°C kilohm
{160-194 OF}
ATF
temperature 1.5-2.7
91-110°C kilohm
{196-230 OF}
ATF
temperature 0.8-1.5
111-130°C kilohm
{232-266 OF}
ATF
temperature 0.54-0.8
131-150°C kilohm
{268 302 OF}
AZ
Inspect continuity between TCM and • Inspect the 4x4 control

4x4 HI mode 4x4 control module
BA 4x4 control module (wiring harness- Continuity
input module
side). • Inspect the related
wiring harness
Inspect continuity between TCM and • Inspect the 4x4 control
4x4 LO mode 4x4 control module
BB 4x4 control module (wiring harness- Continuity
input module
side). • Inspect the related
wiring harness
BC
BD
BE
BF
BG
• TFT sensor
Inspect the TCM terminals AX, AY BU BY and • Inspect the related
BH Sensor GND • Digital TR
CA.(wiring harness-side) ". wiring harness
sensor
BI
BJ
BK
BL (
\
05-13-42
Voltage!
Resistance
OlD OFF • Inspect the OlD OFF
switch button B+ switch
depressed (See 05-13-19 OlD
OlD OFF OlD OFF
BM Engine switch ON OFF SWITCH
switch switch OlD OFF INSPECTION [5R55S])
switch button Below 1.0 V
not depressed
wiring harness
BN
BO - -
BP
BO -
BR -
BS System GND GND Under any condition Continuity • Inspect the related
wiring harness
BT
P, R position
and 2 range sensor
Inspect continuity
between TCM
BU TR2 signal terminals BU and
sensor Not RANGE (TR) SENSOR
BH (wiring Other
continuity INSPECTION [5R55S])
harness-side) .
wiring harness
BV -
BW
BX -
P, R position
and 3 range sensor
Inspect continuity
between TCM
BY TR1 signal terminals BY and
BH (wiring Other
harness-side).
wiring harness
BZ - -
P, N position
and 1 range sensor
Inspect continuity
between TCM
CA TR4 signal terminals CA and
BH (wiring Other
harness-side).
wiring harness
Because this terminal is for serial
communication, goodlno good
CB CAN_H PCM judgment by terminal voltage is not - • Inspect the related
wiring harness
possible. Carry out inspection
according to DTCs.
CC -
CD -
CE - -
Because this terminal is for serial
communication, goodlno good
CF CAN_L PCM judgment by terminal voltage is not - • Inspect the related
wiring harness
possible. Carry out inspection
according to DTCs.
CG - -
CH - -
CI
CJ -
05-13-43
Voltagel
Resistance
• Inspect the solenoid
valve
(See 05-13-34
Solenoid valve Inspect the TCM terminals A, B, C, D, F, I, J and M.
CK Solenoid valve SOLENOID VALVE
power supply (wiring harness-side)
INSPECTION [5R55S))
wiring harness
CL System GND GND Under any condition Continuity • Inspect the related
wiring harness
Engine switch ON B+ • Inspect the AT relay
(See 05-13-38 AT
RELAY INSPECTION
CM IG AT relay
Engine switch OFF Below 1.0 V [5R55S))
wiring harness
CN - - - - -
CO System GND GND Under any condition Continuity • Inspect the related
wiring harness
Engine switch ON B+ • Inspect the AT relay
(See 05-13-38 AT
RELAY INSPECTION
CP IG AT relay
Engine switch OFF Below 1.0 V [5R55S))
wiring harness
TCM REMOVAUINSTALLATION [SRSSS]

id0513c1250800

1 Bracket
2 TCM connector
3 TCM
4 Wiring harness
5 AT relay
6 Bracket
absggw00001526
05-13-44
AUTOMATIC TRANSMISSION REMOVAL/INSTALLATION [SRSSS]
id0513c1249200

3. Remove the following parts.
(1) Under cover
(2) Front propeller shaft (4x4) (See 03-15-2 PROPELLER SHAFT REMOVAUINSTALLATION [5AT].)
(3) Rear propeller shaft (See 03-15-2 PROPELLER SHAFT REMOVAUINSTALLATION [5AT].)
(4) Oxidation catalytic converter.
(5) Front pipe
6. Add ATF and, with the engine idling, inspect the ATF level and inspect for leakage. (See 05-13-16 AUTOMATIC
TRANSMISSION FLUID (ATF) REPLACEMENT [5R55S].) (See 05-13-13 AUTOMATIC TRANSMISSION
FLUID (ATF) INSPECTION [5R55S].)
7. Inspect selector lever operation. (See 05-14-2 SELECTOR LEVER INSPECTION.)
8. Inspect for leakage of ATF from all connecting pOints.
Test item
Service item
Line pressure test Stall speed test
Automatic transmission replacement x
Automatic transmission overhaul x x
Control valve body replacement x x
Torque converter replacement x x
Fluid pump replacement x
Clutch system replacement x
05-13-45
4x2
27.3-3S.3}
40.0-54.5
{4.1-5.5,
29.6-40.1}
WE-C WL-C
~ I I
'-..j
7S.0-9S.0
{S.0-9.9,
~7.6-72.2}
@
I
43.0-54.0 7
?
36.5-46.1
{3.S-4.7,
{4.4-5.5,
31.S-39.S}
I 27.0-34.0}
31.4-46.1~ 31.4-46.1---4,
{3.3-4.7, {3.3-4.7,
23.2-34.0} 23.2-34.0}

arnffw00001939
1 Insulator 6 Torque converter installation nuts

2 Insulator (See 05-13-50 Torque Converter Installation Nuts
Removal Note.)
3 Selector cable bracket
(See 05-13-54 Torque Converter Installation Nuts
4 Selector cable Installation Note.)
5 Cover
05-13-46
7 Crossmember 15 Wiring harness

(See 05-13-51 Transmission Removal Note.) 16 Insulator bracket
8 Transmission mount rubber 17 Oil pipe
9 CKP sensor connector (See 05-13-50 Oil Pipe Removal Note.)
10 AT connector (See 05-13-53 Oil Pipe Installation Note.)
11 Digital TR sensor connector 18 Transmission installation bolt and nut
12 TSS sensor connector 19 Transmission
(See 05-13-51 Transmission Removal Note.)
13 ISS sensor connector (See 05-13-52 Transmission Installation Note.)
14 ass sensor connector
l.
05-13-47
4x4
I 36-S0
40.0-S4.S
{4.1-S.S,
29.6-40.1}
V {3.7-S.0,
27-36}
37.0-S2.0
{3.8-S.3, 7.8-10.8 N·m 27.3-38.3}
27.3-38.3} {80-110 kgf·cm,
69.1-9S.S in·lbf}
43.0-S4.0
{4.4-S.S,
31.8-39.8}
{3.3-4.7,
23.2-34.0}
arnffw00001940 !
1 Insulator 4 ISelector cable

2 Insulator
3 Selector cable bracket
05-13-48
6 Torque converter installation nuts 16 AT connector

(See 05-13-50 Torque Converter Installation Nuts 17 Digital TR sensor connector
Removal Note.)
18 TSS sensor connector
(See 05-13-54 Torque Converter Installation Nuts
Installation Note.) 19 ISS sensor connector
7 Transfer case under cover 20 OSS sensor connector
8 Crossmember 21 Wiring harness
(See 05-13-51 Transmission Removal Note.) 22 Insulator bracket
9 Transmission mount component 23 Oil pipe
10 Transmission mount upper (See 05-13-50 Oil Pipe Removal Note.)
Transmission rubber (See 05-13-53 Oil Pipe Installation Note.)
11
24 Transmission installation bolt and nut
12 Transmission mount lower
Transfer case motor connector 25 Transmission and transfer case
13
(See 05-13-51 Transmission Removal Note.)
14 Transfer case speed sensor connector (See 05-13-52 Transmission Installation Note.)
15 CKP sensor connector
4x4
38.0-52.0 N·m
{3.9-5.3 kgf·m,
28.1-38.3 tt·lbf}
absggw00001540
26 ITransfer case 27 ITransmission
05-13-49
Torque Converter Installation Nuts Removal Note
1. Remove the cooling fan.
2. Hold the crankshaft pulley to prevent the drive
plate from rotating.
absggw00001804
3. Remove the torque converter nuts.
absggw00001805
Oil Pipe Removal Note

1. Remove the oil pipe installation bolt and nut.
NUT
absggw00001810
05-13-50
Transmission Removal Note
Warning
• Verify that the transmission is securely supported by the jack. If the transmission falls, serious
injury or death and damage to the vehicle could result. Before removing the transmission make
sure that the jack is securely supporting the transmission.
Caution
• To prevent the torque converter and transmission from separating, remove the transmission
without tilting it toward the torque converter.
1. Remove the front differential mount rubber.
MOUNT RUBBER
absggw00001541
2. Support the transfer case side securely using one

transmission jack.
Caution
• Do not allow the transmission jack to
interfere with the transmission mount
bracket bolts, otherwise the bolts could
be damaged.
absggw00001806
4. Support the transmission securely using a

transmission jack.
5. Support the front side of engine securely using a
transmission jack.
absggw00001807
05-13-51
6. Remove the transmission installation bolt.
absggw00001542
7. Remove the transmission while setting it out of

the way so that it does not contact the differential.
absggw00001543
Transmission Installation Note
Warning
• Verify that the transmission is securely supported by the jack. If the transmission falls, serious
injury or death and damage to the vehicle could result. Before removing the transmission make
sure that the jack is securely supporting the transmission.
Caution
• To prevent the torque converter and transmission from separating, remove the transmission
without tilting it toward the torque converter
1. Support the front side of engine securely using a transmission jack.

2. Support the transmission and transfer case ,.-----------------------,
securely using a transmission jack.
absggw00001808
05-13-52
3. Install the transmission while setting it out of the
way so that it does not contact the differential.
absggw00001544
4. Tighten the transmission installation bolts and

nuts.
Tightening torque
37-52 N·m {3.8-5.3 kgf·m, 28-38 ft.lbf}
absggw00001542
5. Install the front differential mount rubber.
Tightening torque
54.9-80.4 N·m {5.6-8.1 kgf.m, 41-59 ft.lbf}
MOUNT RUBBER
absggw00001541
Oil Pipe Installation Note

1. Install the oil pipe installation bolt and nut.
Tightening torque
7.8-10.7 N·m {80-109 kgf·cm, 69.1-94.7
in.lbf}
NUT
absggw00001810
05-13-53
Torque Converter Installation Nuts Installation Note
1. Hold the crankshaft pulley to prevent the drive
plate from rotating.
Caution
• Loosely and equally tighten the torque
converter nuts, then further tighten them
to the specified tightening torque.
absggw00001804
2. Tighten the new torque converter installation nuts.
Tightening torque
40.0-54.5 N·m {4.1-5.5 kgf.m, 29.6-40.1
ft.lbf}
absggw00001805
TORQUE CONVERTER INSPECTION [5R55S]

id0513c1711900
Caution
• Do not use water-based cleaners or mineral spirits to clean or flush the torque converter or
transmission damage will occur. Use only clean ATF designated for the transmission and
converter being serviced.
• The torque converter drain plug and seal are not reusable. If equipped, discard the drain plug and
seal, then install a new drain plug component.
• If a new or remanufactured torque converter is not being installed, the following steps must be completed.
1. With the torque converter on a bench, pour a small ATF from the torque converter onto an absorbent white
tissue or through a paper filter and examine the ATF.
2. Observe the color and odor of the ATF. The ATF should be red, not brown or black. Odor may indicate an
overheating condition such as clutch disc or band failure.
3. Examine the stain on the tissue for evidence of particles (spec of any kind). Examine the fluid level indicator for
signs of antifreeze (gum or varniSh).
• If particles are present in the fluid or there is evidence of engine coolant or water, a new torque converter
must be installed.
• If there are no particles or contamination present, drain the remainder of the ATF from the torque converter.
4. Add 1.9 L {2.0 US qt, 1.7 Imp qt} of clean ATF into the converter and agitate by hand.
5. Thoroughly drain the fluid.
05-13-54
TORQUE CONVERTER REMOVAL/INSTALLATION [5R55S]
id0513c171 01 00
Removal
1. Remove the transmission. (See 05-13-45 AUTOMATIC TRANSMISSION REMOVAL/INSTALLATION [5R55S].)
Caution
• The oil seal is easily damaged by the sharp edges of the torque converter splines. Do not let the
splines contact the oil seal.
• Do not drop the torque converter.
• Do not pinch fingers.
2. Using the SSTs, remove the torque conv~rter.
Installation
Caution
• Do not damage the fluid pump gear O-ring when installing torque converter.
• Make sure the converter hub is fully engaged in the pump support and gear and rotates freely. Do
not damage the hub seal.
• If the torque converter slides out, the hub seal may be damaged.
1. Lubricate the converter hub with clean ATF.
Warning
• The torque converter can fall out if the
transmission is tipped. Failure to follow
these instructions may cause personal
injury.
b5r5za00000286
2. Using the SST, install the torque converter by

pushing and rotating.
3. Install the automatic transmission. (See 05-13-45
AUTOMATIC TRANSMISSION REMOVAL!
4. Perform the mechanical system test. (See 05-13-
4 MECHANICAL SYSTEM TEST [5R55S].)
05-13-55
OIL SEAL (FLUID PUMP) REPLACEMENT [5R55S]
id0513c1712000
Removal
Caution
• The oil seal is easily damaged by the sharp edges of the torque converter splines. Do not let the
splines contact the oil seal.
• Do not drop the torque converter.
• Do not pinch fingers.
2. Remove the torque converter. (See 05-13-55 TORQUE CONVERTER REMOVAL/INSTALLATION [5R55S].)
Caution
• Do not to damage the bushing on the fluid pump body.
3. Using the SST, remove the fluid pump seal.
b5r5za00000295
Installation
1. Install a new seal onto the SST.
Note
• Check and make sure that the garter spring
in the seal has not popped off of the
converter hub seal.
arnffw00001959
2. Using the SST, install the converter hub seal.

3. Install the torque converter. (See 05-13-55
TORQUE CONVERTER REMOVAL!
4. Install the automatic transmission. (See 05-13-45
AUTOMATIC TRANSMISSION REMOVAL/
5. Perform the mechanical system test. (See 05-13-
4 MECHANICAL SYSTEM TEST [5R55S].)
arnffw00001960
05-13-56
OIL SEAL (EXTENSION HOUSING) REPLACEMENT [SRSSS]
id0513c1710000
Removal (4x2)
1. Remove the propeller shaft. (See 03-15-2 PROPELLER SHAFT REMOVAL/INSTALLATION [5AT].)
2. Using the SST, remove the extension housing
seal.
arnffv00000522
Removal (4x4)
1. Remove the transfer case. (See 03-16-7 TRANSFER CASE REMOVAL/INSTALLATION [5R55S].)
2. Using the SSTs, remove the extension housing
seal.
Installation (4x2)
1. Using the SST, install the extension housing seal.
Note
• Make sure the extension housing seal is
correctly installed onto the SST and the
garter spring is in the correct position.

[5AT].)
3. I nspect the ATF level for leakage. (See 05-13-13
AUTOMATIC TRANSMISSION FLUID (ATF)
arnffv00000545
Installation (4x4)
1. Using the SST, install the extension housing seal.
Note
• Make sure the extension housing seal is
correctly installed onto the SST and the
garter spring is in the correct position.
2. Install the transfer case. (See 03-16-7

TRANSFER CASE REMOVAL/INSTALLATION
{ [5R55S].)
\ 3. Inspect the ATF level for leakage. (See 05-13-13
AUTOMATIC TRANSMISSION FLUID (ATF)
b5r5za00000280
05-13-57
EXTENSION HOUSING GASKET REPLACEMENT [SRSSS]
id0513c1254300
Removal (4x2)
4. Lower the transmission.
Caution
• The parking pawl, parking pawl return spring and parking pawl shaft could fall out during removal
of the extension housing.
5. Remove the extension housing.
b5r5za00000011
6. Remove and discard the extension housing

gasket.
absggw00001629
Removal (4x4)
3. Remove the crossmember and Transmission mount component. (See 05-13-45 AUTOMATIC TRANSMISSION
4. Remove the transfer case. (See 03-16-7 TRANSFER CASE REMOVAUINSTALLATION [5R55S].)
Caution
• The parking pawl, parking pawl return spring and parking pawl shaft could fall out during removal
of the extension housing.
5. Remove the extension housing.
05-13-58
6. Remove and discard the extension housing
gasket.
absggw00001630
Installation (4x2)
1. Clean the extension housing and install new
extension housing gasket.
2. Make sure that the park pawl is installed correctly.
Caution
• Make sure the parking lever actuating rod
is correctly seated into the case parking
rod guide cup.
absggw00001629
3. Install the extension housing.
Tightening torque
28-32 N·m {2.9-3.2 kgf.m, 21-23 ft.lbf}
4. Install the crossmember and transmission mount

rubber. (See 05-13-45 AUTOMATIC
TRANSMISSION REMOVAUINSTALLATION
[5R55S])
PROPELLER SHAFT REMOVAUINSTALLATION
[5AT].)
7. Inspect the ATF level for leakage. (See 05-13-13
AUTOMATIC TRANSMISSION FLUID (ATF) INSPECTION [5R55S].)
Installation (4x4)
1. Clean the extension housing and install new
extension housing gasket.
2. Make sure that the park pawl is installed correctly.
Caution
• Make sure the parking lever actuating rod
is correctly seated into the case parkin-g
rod guide cup.
absggw00001630
05-13-59
3. Install the extension housing.
Tightening torque
28-32 N·m {2.9-3.2 kgf.m, 21-23 ft.lbf}
4. Install the transfer case. (See 03-16-7

TRANSFER CASE REMOVAUINSTALLATION
[5R55S].)
5. Install the crossmember and Transmission mount
component. (See 05-13-45 AUTOMATIC
TRANSMISSION REMOVAUINSTALLATION
[5R55S])
[5AT].)
8. Inspect the ATF level for leakage. (See 05-13-13 AUTOMATIC TRANSMISSION FLUID (ATF) INSPECTION
[5R55S].)
05-13-60
CONTROL VALVE BODY REMOVAL [5R55S]
id0513c1710600
On-Vehicle Removal
Warning
• A hot transmission and ATF can cause severe burns. Turn off the engine and wait until they are
Caution
• Clean the transmission exterior thoroughly with a stream cleaner or cleaning solvents before
removal.

absggw00001183

b5r5za00000015
8. Remove the detent spring.
05-13-61
9. Remove the low/reverse brake servo component.
Caution
pins.
b5r5za00000017

b5r5za00000018
11. Remove the control valve body.
b5r5za00000019
05-13-62
CONTROL VALVE BODY INSTALLATION [5R55S]
id0513c1710700
On-Vehicle Installation
1. Install the SSTs into the transmission case.
2. Using the SSTs, Install the control valve body and

loosely install the bolts.
(1) Install the short bolt.
(2) Install the bolt with the larger head.
(3) Install the remaining bolts.
3. Remove the SSTs and loosely install the screw.

4. Tighten the bolts in the sequence shown.
Tightening torque
9-11 N·m {92-112 kgf·cm, 80-97 in.lbf}
05-13-63
b5r5za00000270
5. Install the detent spring.
Tightening torque
9-11 N·m {92-112 kgf·cm, 80-97 in.lbf}

Caution
and not damaged. If damaged, a
b5r5za00000272
05-13-64
sequence shown.
Tightening torque
7-9 N·m {72-91 kgf·cm, 62-79 in.lbf}
)
b5r5za00000273
8. Install the reverse servo. Tighten the bolts in the

sequence shown in 2 stages.
Tightening torque
Stage 1: 5 N·m {51 kgf·cm, 44 in·lbf}
Stage 2: 10-12 N·m {102-122 kgf.cm, 89-
106 in·lbf}
Caution
damaged.
b5r5za00000274

fluid filter.
Tightening torque
9-11 N·m {92-112 kgf·cm, 80-97 in·lbf}
Note
0'----0
10. Install the transmission fluid pan gasket on the

pan. Q
Note
reusable, clean and inspect for damage. If GASKET
absggw00001562
11. Install the transmission fluid pump and gasket,

12. Tighten the bolts in a crisscross sequence.
Tightening torque
9.5-11.5 N·m {97-117 kgf·cm, 85-101
in·lbf}
Caution
• Damage will occur to the solenoid body
component if the screw is tightened
above specification.
05-13-65
13. Install and lubricate new O-rings on the AT
connector and connect the connector.
Tightening torque
Note
• Clean the area around connector to prevent
contamination of the AT connector.
• Use petroleum jelly to lubricate the O-rings
to aid in the installation process.
absggw00001183
14. Remove the insulator bracket. (See 05-13-45
AUTOMATIC TRANSMISSION REMOVAU
15. Remove the CKP sensor insulator. (See 05-13-45 AUTOMATIC TRANSMISSION REMOVAUINSTALLATION
[5R55S].)
16. Remove the digital TR sensor insulator. (See 05-13-45 AUTOMATIC TRANSMISSION REMOVAL/
18. Add ATF and, with the engine idling, inspect the ATF level and for leakage. (See 05-13-13 AUTOMATIC
TRANSMISSION FLUID (ATF) INSPECTION [5R55S].)
05-13-66
OIL COOLER FLUSHING [5R55S]
id0513c1710900
Note
• If the automatic transaxle is replaced, flush and inspect the oil cooler.
• When replacing the automatic transaxle, inspect the oil cooler together with flushing it using the following
procedure, and with the oil cooler hose removed.
1. Remove the oil cooler. (See 05-13-68 OIL COOLER REMOVAUINSTALLATION [5R55S].)
2. Disconnect the oil cooler hose.
3. Set a clean fluid pan up to the oil cooler hose inlet.
4. Blow 491-882 kPa {5-9 kgf/cm 2 , 72-127 psi} of compressed air from the oil cooler hose outlet to drain
remaining oil. .
5. Add new ATF from the oil cooler hose outlet and blow 491-882 kPa {5-9 kgf/cm 2 , 72-127 psi} of
compressed air to flush. (Repeat 2 or 3 times)
6. Verify that none of the following foreign material is mixed in with the drained ATF:
• Large metal fragments of ~ 0.5 mm {0.02 mm} or more that cannot pass through the oil strainer
• Fibrous clutch facing
7. Repeat the procedures from Step 3 to 4 and flush the inside of the oil cooler.
8. If foreign material such as metal fragments or clutch facing remains even after the oil cooler is flushed
repeatedly, replace the oil cooler (radiator).
OIL COOLER
(RADIATOR) OIL PAN
t~~ ......... COMPRESSED

AIR
'*
FRONT
~
FRONT
COMPRESSED AIR
~~gJ
COMPRESSED AIR
05-13-67
OIL COOLER REMOVAL/INSTALLATION [5R55S]
id0513c1248700
3. Drain the engine coolant.
4. Remove the following parts.
(1) Splash shield
(2) Under cover
(3) Front bumper
7. Add the engine coolant.
8. Add ATF to the specified level. (See 05-13-16 AUTOMATIC TRANSMISSION FLUID (ATF) REPLACEMENT
[5R55S].)
9. Inspect for oil leakage from the oil pipes and oil hoses.
10. Inspect for coolant from the hoses.
11. Inspect for engine coolant leakage.
12. Inspect the ATF level and condition. (See 05-13-13 AUTOMATIC TRANSMISSION FLUID (ATF) INSPECTION
[5R55S].)
05-13-68
~
FRONT
+
FRONT
.#f
FRONT
{90-129 kgf·cm,
77.9-112.4 in·lbf}
arnffw00001945
Oil pipe 2 Hose clamp

(See 05-13-70 Oil Pipe, Hose clamp, Oil hose (See 05-13-70 Oil Pipe, Hose clamp, Oil hose
Installation Note.) Installation Note.)
05-13-69
3 Oil hose 6 Braket

(See 05-13-70 Oil Pipe, Hose clamp, Oil hose 7 Radiator (in tank oil cooler)
Installation Note.) (See 05-13-70 Radiator (In Tank Oil Cooler)
4 Cover Installation Note.)
5 Oil cooler
Radiator (In Tank Oil Cooler) Irlstallation Note

1. The automatic transmission oil cooler flushing must be performed whenever a transmission is removed for
service because the existing fluid may be contaminated, and to prevent contamination of new fluid.
Note
• Flushing must be performed after installation of the overhauled or replaced transmission.
2. Follow the instructions in the manufacturer's publication for flushing operation.
Oil Pipe, Hose clamp, Oil hose Installation Note

1. Apply compressed air to cooler-side opening, and
blow any remaining grime and foreign material
from the cooler pipes. Compressed air should be
applied for more than 1 min.
acxuuw00000609
2. Align the marks, and slide the oil hose onto the oil
pipe until it is fully seated as shown.
3. Install the hose clamp onto the hose.
OIL
HOSE
arnffwOOOO 1946
Note
• If reusing the hose, install the new hose
clamp exactly on the mark left by the
previous hose clamp. Then apply force to the
hose clamp in the direction of the arrow in
order to fit the clamp in place.
4. Verify that the hose clamp does not interfere with

any other components.
absggw00001709
05-13-70
DRIVE PLATE REMOVAUINSTALLATION [5R55S)
id0513c1250200

1 Backing plate
2 Drive plate
(See 05-13-71 Drive Plate Removal Note.) 3
(See 05-13-71 Drive Plate Installation Note.)
3 Plate
4 Spacer
absggw00001705
Drive Plate Removal Note

1. Set the SST or equivalent against the drive plate.
• I
2. Remove the bolts and the drive plate.
absggw00001706
Drive Plate Installation Note

1. Remove the sealant from the bolt holes in the crankshaft.
2. Install the drive plate.
3. Install the backing plate.
4. Set the SST or equivalent against the drive plate.
5. Tighten the drive plate mounting bolts in two or • I
three steps in the order as shown in the figure.
Tightening torque
151.3-161.1 N·m
{15.5-16.4 kgf·m, 111.6-118.8 ft.lbf}
6. Install the transmission. (See 05-13-45

AUTOMATIC TRANSMISSION REMOVAL!
absggw00001707
05-13-71
05-14 AUTOMATIC TRANSMISSION SHIFT MECHANISM

AUTOMATIC TRANSMISSION SELECTOR CABLE
SHIFT MECHANISM ADJUSTMENT .................... 05-14-2
LOCATION INDEX ................. 05-14-1 SELECTOR CABLE
SELECTOR LEVER INSPECTION ..... 05-14-2 REMOVAUINSTALLATION ......... . 05-14-3
SELECTOR LEVER
REMOVAUINSTALLATION ......... . 05-14-4
AUTOMATIC TRANSMISSION SHIFT MECHANISM LOCATION INDEX

id051400254000
absggw00001005
Selector lever 2 Selector cable

(See 05-14-2 SELECTOR LEVER INSPECTION.) (See 05-14-2 SELECTOR CABLE ADJUSTMENT.)
(See 05-14-4 SELECTOR LEVER REMOVAU (See 05-14-3 SELECTOR CABLE REMOVAU
05-14-1
SELECTOR LEVER INSPECTION
id051400255500
1. Turn the engine switch to the ON position (engine off).

2. With the brake pedal depressed, verify that there
is a "click" at each range when shifted.
3. Verify that the selector lever can be shifted.
4. Verify that there is a "click" at each position when
shifted from the P position to the 1 range. BUTTON MUST BE
• DEPRESSED
r-"-... BUTTON NEED NOT

Y BE DEPRESSED
arnffw00001928
5. Verify that the positions of the selector lever and

the indicator are aligned.
ADJUSTMENT [5R55S].)
6. Verify that the vehicle operates in each selected
range.
absggw00001014
SELECTOR CABLE ADJUSTMENT

id051400256100
1. Remove the console.

2. Shift the selector lever to the N position.
3. Loosen the nut at approx. 90°.
4. Adjustment the end of the selector cable position.
5. Tighten the nut.
Tightening torque
9.8-18.2 N·m {100-185 kgf.cm, 87-161
in·lbf}
6. Install the console.
NUT
absggw00001019
(
\.
05-14-2
SELECTOR CABLE REMOVAUINSTALLATION
id051400256200

3. Shift the selector lever to the P position.
7.8-10.7
{80-109,
69.1-94.7}
7.8-10.7
{80-109,
69.1-94.7}
Digital TR sensor insulator Selector cable

Selector cable bracket (See 05-14-3 Selector Cable Installation Note.)
Selector Cable Installation Note

2. Loosen the nut at approx. 90 0
•

4. Tighten the nut.
Tightening torque
9.8-18.2 N·m {100-185 kgf·cm, 87-161
in.lbf}
NUT
absggw00001019
05-14-3
SELECTOR LEVER REMOVAL/INSTALLATION
id051400255700

3. Shift the selector lever to the P position.
1 Connector
2 Selector cable
3 9.8-14.7
'7' '.')
(See 05-14-4 Selector Cable Installation Note.) {10o-149,
3 Selector lever
4 Bulb
5 Selector lever bracket
5. Install in the reverse order of removal. I

arnffw00001930
Selector Cable Installation Note

2. Loosen the nut at approx. 90°.
4. Tighten the nut.
Tightening torque
9.8-18.2 N·m {100-185 kgf·cm, 87-161
in·lbf}
NUT
absggw00001019
05-14-4
TECHNICAL DATA

TRANSMISSIONfTRANSAXLE
......................... . 05-50-1
TRANSMISSIONfTRANSAXLE [5R55S]
id0550h1800400
Item Specification
ATF Type: Mercon® V

Line pressure (pressure control A, pressure control B)

Positionlrange
Idle Stall
PIN 793 {8.09, 115} 793 {8.09, 115}
R 793 {8.09, 115} 2,138 {21.80, 310}
D, 3, 2,1 793 {8.09, 115} 1,520 {15.47, 220}
Line pressure (pressure control C)

Position/range
Idle Stall
PIN 27 {0.28, 4} o {O, O}
R 793 {8.09, 115} 793 {8.09, 115}
D, 3, 2,1 27 {0.28, 4} o {O, O}
IEnglne stall speed
Engine type rpm
WL-C 2,700
WE-C 2,900

ATF temperature eC eF}) Resistance (kilohm)
-40--20 {-40--4} 284-967
-19--1 {-3-30} 100-284
0-20 {32-68} 37-100
21-40 {70-104} 16-37
41-70 {106-158} 5-16
71-90 {160-194} 2.7-5
91-110 {196-230} 1.5-2.7
111-130 {232-266} 0.8-1.5
131-150 {268-302} 0.54-0.8
TSS sensor resistance

Resistance (ohm) Temperature eC eF})
226-390 -20 {4}
325-485 21 {70}
492-738 150 {302}
ISS sensor resistance

Resistance (ohm) Temperature eC eF})
226-390 -20 {4}
325-485 21 {70}
492-738 150 {302}
05-50-1
TECHNICAL DATA
ass sensor resistance
Resistance (ohm) Temperature (Oe eF})
226-390 -20 {4}
325-485 21 FO}
492-738 150 {302}
Solenoid valve resistance)

Terminals Solenoid valve Resistance (ohm)
D-I' Shift solenoid A 16-45
F-I Shift solenoid 8 16-45
8-1 Shift solenoid C 16-45
E-I Shift solenoid D 16-45
0-1 Pressure control solenoid A 3.3-7.5
M-I Pressure control solenoid 8 3.3-7.5
G-I Pressure control solenoid C 3.3-7.5
H-I TCC control solenoid 9-16
Clutch
Item Specification
Specified fluid SAE J 1703, FMVSS 116 DOT-3
Clutch pedal stroke 152 mm {5.98 in}
Clutch pedal play 5-15 mm {0.20-0.59 in}
Clutch pedal push rod play (Reference value) 0.1-0.5 mm {0.004-0.020 in}
Clutch disengagement stroke (Reference value)
A: 100-130 mm {3.94-5.11 in}
[R15M-D]
Clutch disengagement stroke (Reference value)
A: 110-125 mm {4.34-4.92 in}
[S15M-D, S15MX-D]
Clutch disc maximum depth 0.6 mm {0.024 in}
Clutch cover maximum clearance 0.3 mm {0.012 in}
Clutch cover maximum height difference 1.0 mm {0.039 in}
Clutch disc minimum depth 0.3 mm {0.012 in}
Clutch disc maximum runout 0.7 mm {0.028 in}
Flywheel maximum runout [R15M-D] 0.1 mm {0.004 in}
Dual-mass flywheel maximum runout [S15M-D,
1.5 mm {0.059 in}
S15MX-D]
Manual Transmission [S15M-O, S15MX-O]

Item Specification
Vehicle speed sensor (VSS) voltage [S15M-D] 5 Vor less
Shift control case oil [S15M-D] Capacity (approx. quantity): 220-260 ml {220-260 cc, 13.42-15.86
cu in}
05-50-2
SERVICE TOOLS
05-60 SERVICE TOOLS

TRANSMISSION SST ............... 05-60-1
TRANSMISSION SST
dcf05600000Ow01
49 S120 440 49 G030 797 49 E011 1AO
Mainshaft Handle Ring gear brake

holder
( ~ (fIP set
490259770B 49 SE01 310A 49 1285071
Flare nut Clutch disc Bearing puller

wrench centering tool
~ a::::):::l:Bj I
~
49 F028202 49 G030 795 49 G028 203
Bush Installer Oil seal Installer Support
05-60-1
SERVICE TOOLS
TRANSMISSION SST [5R55S]
id0560h1500200
1: Mazda SST number
Example
1:49 UN2O. 50.72
2:20.5-0.72
Holding Tool
1:- 1:- 1 :-
2:10.0.-0.0.1 2:1o'o'-DO.O.9 2:30.7-0.0.4
Slide Hammer Rubber Tip Air Pressure

Nozzle Gauge,
Transmission
Fluid
1:- 1:- 1 :-
2:30.7-0.91 2:30.7-30.9 2:30.7-334
Handle, Torque
u) ))
Remover, Aligner, Valve
Converter u) )) Torque
Converter Fluid
Body (2
required)
Seal
1:- 1:49 UN3O. 7351 1:-

2:30.7-349 2:30.7-351 2:30.7-433-0.1,
30.7 -433-0.2,
Installer, Torque Alignment 30.7-433-0.3
Converter Fluid Gauge, TR
Seal Sensor Transmission
Test Plate and
Gasket
1:- 1:49 UN3O. 7437 1:49 UN3O.
2:30.7-435 2:30.7-437 7D465O.
2:3o'7-D465
Installer, Adapter, Fluid
Transmission Level and Fill Fluid
Extension Plug Transporter/
Housing Fluid Evacuator/
Seal Injector
1:- 1 :- 1:-
2:30.8-0.0.2 2:30.8-375 2:416-Do'o'2
Installer, Remover, Input Vacuum Pump

Transmission Shaft Oil Seal Kit
Extension
Housing Oil
Seal
1:49 Eo'11 1Ao'
2:-
Brake Set, Ring

Gear
05-60-2
STEERING
GENERAL PROCEDURES ... 06-10 TECHNICAL DATA .......... 06-50

POWER STEERING ......... 06-14 SERVICE TOOLS ........... 06-60

GENERAL PRECAUTION
(STEERING) ..................... 06-10-1
GENERAL PRECAUTION (STEERING)

dcf06100000Ow01
Wheels and Tire Installation

torque.
Tightening torque
88.2-117.6 N·m {9.00-11.99 kgf.m, 65.06-86.73 ft.lbf}
1. Disconnect the negative battery cable before performing any work that requires handling of connectors. (See
01-17-2 BATTERY REMOVAUINSTALLATION.)
Power Steering Components Removal/Installation

1. If any power steering fluid line has been disconnected anytime during the procedure, add ATF M-III or
( equivalent (e.g. Dexron@II), bleed the fluid lines, and inspect for leakage after the procedure has been
completed.
II
06-10-1
POWER STEERING
06-14 POWER STEERING

STEERING LOCATION INDEX ...•.•.. 06-14-2 STEERING GEAR AND LINKAGE
AIR BLEEDING •......•••.•..•..... 06-14-3 REMOVAUINSTALLATION .......... 06-14-10
POWER STEERING FLUID STEERING GEAR AND LINKAGE
INSPECTION .•.•.••.•.•.......•.. 06-14-3 DiSASSEMBLy/ASSEMBLy •....•... 06-14-11
STEERING WHEEL AND COLUMN STEERING GEAR AND LINKAGE
INSPECTION •.•....•.•.•••.•.•..• 06-14-5 INSPECTION ••.••••........••...• 06-14-13
STEERING WHEEL AND COLUMN POWER STEERING OIL PUMP
REMOVAUINSTALLATION .......•.. 06-14-6 REMOVAUINSTALLATION .••....... 06-14-14
STEERING SHAFT INSPECTION ...•.. 06-14-9 POWER STEERING OIL PUMP
DISASSEMBLy/ASSEMBLy ....•...• 06-14-15
06-14-1
POWER STEERING
STEERING LOCATION INDEX
dcf061400000w01
DBR614ZWB001
1 Power steering fluid tank 4 Steering gear and linkage

(See 06-14-3 AIR BLEEDING.) (See 06-14-10 STEERING GEAR AND LINKAGE
(See 06-14-3 POWER STEERING FLUID REMOVAUINSTALLATION.)
INSPECTION.) (See 06-14-11 STEERING GEAR AND LINKAGE
2 Steering wheel and column DISASSEMBLY/ASSEMBLY.)
(See 06-14-5 STEERING WHEEL AND COLUMN (See 06-14-13 STEERING GEAR AND LINKAGE
(See 06-14-6 STEERING WHEEL AND COLUMN 5 Power steering oil pump
REMOVAUINSTALLATION.) (See 06-14-14 POWER STEERING OIL PUMP
3 Steering shaft REMOVAUINSTALLATION.)
(See 06-14-9 STEERING SHAFT INSPECTION.) (See 06-14-15 POWER STEERING OIL PUMP
06-14-2
POWER STEERING
AIR BLEEDING
dcf061400000w02
Caution
• Do not turn the steering wheel during the fluid level inspection, otherwise the fluid level changes
and cannot be inspected correctly.
1. Inspect the fluid level. (See06-14-3 POWER STEERING FLUID INSPECTION.)

2. Jack up the front of the vehicle and support it on safety stands.
3. Turn the steering wheel fully to the left and right several times with the engine not running.
4. Reinspect the fluid level.
• If it has dropped, add fluid.
5. Repeat Steps 3 and 4 until the fluid level stabilizes.
6. Lower the vehicle.
7. Start the engine and let it idle.
8. Turn the steering wheel fully to the left and right several times.
9. Verify that the fluid is not foamy and that the fluid level has not dropped.
• If the fluid level has dropped, add fluid as necessary and repeat Steps 8 and 9.
POWER STEERING FLUID INSPECTION

dcf06143204Ow01
Fluid Level Inspection

1. Inspect the power steering fluid level.
• Add fluid to the specified level as necessary.
Power steering fluid type

ATF M-III or equivalent (e.g. Dexron®lI)
Power steering fluid capacity (approx. quantity)

1.1 L {1.2 US qt, 1.0 Imp qt}
Fluid Leakage Inspection

1. Start the engine and let it idle.
2. Turn the steering wheel fully to the left and right to apply fluid pressure.
Caution
• If the steering wheel is kept in the fully turned position for more than 5 seconds, the fluid
temperature will rise excessively and adversely affect the oil pump.
3. Inspect for fluid leakage at the points indicated in

the figure.
• If fluid leakage is found, replace related parts.
DBR614ZWB999
06-14-3
POWER STEERING
Fluid Pressure Inspection
1. Assemble the SSTs as shown in the figure.
2. Mark both hose connections to ensure that the
hose is reinstalled in its original position.
3. Disconnect the pressure pipe from the oil pump,
and connect the SSTs.
Tightening torque
29.4-44.1 N·m {3.00-4.49 kgf·m, 21.7-32.5
ft.lbf}
A6E0612W101
4. Connect the SSTs (49 1232 670B and 49 H002

671) to the SST (49 G032 3A4A)
5. Bleed the air from the system. (See 06-14-3 AIR
BLEEDING.)
6. Open the gauge valve fully.
7. Start the engine and turn the steering wheel fully
left and right to raise the fluid temperature to 50-
60 DC {122-140 OF}.
Caution
• If the valve is left closed for more than 5
s, the fluid temperature will increase
excessively and adversely affect the oil
pump.
8. Close the gauge valve completely. Increase the THERMOMETER

engine speed to 1,000-1,500 rpm and measure 50-60°C {122-140°F}
the fluid pressure generated by the oil pump. If
the pressure is not within the specification, repair
or replace the oil pump component.
Oil pump fluid pressure

9.3-9.8 MPa {94.8-99.9 kgf/cm 2 , 1348-
1421 psi}
Caution
• If the steering wheel is kept in the fully
turned position for more than 5 s, the
fluid temperature will rise excessively
and adversely affect the oil pump.
9. Open the gauge valve fully and increase the engine speed to 1,000-1,500 rpm
10. Turn the steering wheel fully to left and right and .--------------------------,
measure the fluid pressure generated at the gear 5dH~~~?~~T~~00F}
housing. If the pressure is not within the
specification, repair or replace the steering gear
component. OPEN VALVE _~~
COMPLETELY r~~~-*-r,
Gear housing fluid pressure
9.30-9.79 MPa {94.8-99.8 kgf/cm 2 , 1348-
1419psi}
11. Remove the SSTs. Install and tighten the

pressure pipe to the specified torque. DBR614ZWB604
Tightening torque
31.4-47.0 N·m {3.21-4.79 kgf·m, 23.2-34. ft.lbf}
06-14-4
POWER STEERING
STEERING WHEEL AND COLUMN INSPECTION
dcf061432010w01
Steering Wheel Play Inspection

1. With the wheels in the straight-ahead position, gently turn the steering wheel to the left and right and verify that
the play is within the specification.
• If the play exceeds the specification, either the steering joints are worn or the backlash of the steering gear
is excessive. Correct as necessary.
Steering wheel play

0-30 mm {0-1.18 in}
Steering Wheel Looseness Inspection

1. Move the steering wheel as shown in the figure to
inspect for column bearing wear, steering shaft
joint play, steering wheel looseness, and column
looseness.
• Repair or replace as necessary.
DBR614ZW301
Steering Wheel Effort Inspection

1. Inspect the following points:
• Tire size and tire pressure
• Fluid level
2. With the vehicle on a hard, level surface, put the wheels in the straight-ahead position.
3. Remove the air bag module.
Warning
• Handling the air bag module improperly can accidentally deploy the air bag module, which may
seriously injure you. Read AIR BAG SYSTEM WARNINGS before handling the air bag module. (See
08-10-2 SERVICE WARNINGS.) (See 08-10-3 SERVICE CAUTIONS.)
4. Start the engine and warm the power steering fluid to 50-60 DC {122-140 OF}.
5. Measure the steering wheel effort using a torque ,----------------------,
wrench. '-'!I
• If not within the specification, verify the _
following:
No air in steering system
- No fluid leakage at hose or connectors
- Function of oil pump and steering gear
Steering wheel effort

7.8 N·m {80 kgf·cm, 58 in.lbf} max.
Note
DBR614ZW302
• To determine whether the steering effort is
satisfactory or not, perform the inspection on
another vehicle of the same model and under the same conditions, and compare the results.
• The steering wheel effort varies with'conditions as shown below.
Road conditions, such as dry or wet, and asphalt or concrete.
- Tire conditions, such as brand, wear, and tire pressure.
06-14-5
POWER STEERING
STEERING WHEEL AND COLUMN REMOVAUINSTALLATION
dcf06143201Ow02
Warning
seriously injure you. Read AIR BAG SYSTEM WARNINGS before handling the air bag module. (See
08-10-2 SERVICE WARNINGS.) (See 08-10-3 SERVICE CAUTIONS.)

7.9-11.7 N·m WITHOUT AIR BAG SYSTEM

{81-119 kgf·cm,
1
15.7-22.5
{1.60-2.29,
11.6-16.6}
/
~
18-25
:"
{1.8-2.5,
13-18}
19.6-26.5
~
2'O0-2'70'
14.5--19.5}
j .
~~
19.6-26.5
{2.00-2.70,
14.5-19.5}

DBR614ZWB101
1 Lower panel 5 Steering wheel

(See 09-17-10 LOWER PANEL REMOVAU (See 06-14-7 Steering Wheel Removal Note.)
INSTALLATION.) (See 06-14-8 Steering Wheel Installation Note.)
2 Horn cap 6 Column cover
3 Air bag module (See 09-17-8 COLUMN COVER REMOVAU
(See 08-10-4 DRIVER-SIDE AIR BAG MODULE INSTALLATION. )
REMOVAUINSTALLATION.) 7 Clock spring
4 Locknut (See 08-10-7 CLOCK SPRING REMOVAU
INSTALLATION.)
06-14-6
POWER STEERING
8 Combination switch 13 Steering lock mounting bolts

(See 09-18-9 COMBINATION SWITCH REMOVAU (See 06-14-7 Steering Lock Mounting Bolts
INSTALLATION.) Removal Note.)
9 Steering shaft (See 06-14-8 Steering Lock Mounting Bolts
(See 06-14-8 Steering Shaft Installation Note.) Installation Note.)
10 Universal joint 14 Steering lock component
11 Boot 15 Outer cylinder
(See 06-14-7 Outer Cylinder Removal Note.)
12 Intermediate shaft
Steering Wheel Removal Note
Caution
• Do not try to remove the steering wheel by hitting the shaft with a hammer. The column will
collapse.
1. Set the vehicle in the straight-ahead position.

2. Remove the steering wheel using a suitable puller.
Steering Lock Mounting Bolts Removal Note

1. Make a groove in the heads of the steering lock
mounting bolts using a chisel and a hammer.
2. Remove the bolts using a flathead screwdriver.
3. Disassemble the steering lock component.
DBR614ZWB601
Outer Cylinder Removal Note

1. Turn the key to the ACC position.
2. Push the pin and remove the outer cylinder.
~---m
PIN
DBR614ZWB606
06-14-7
POWER STEERING
Steering Lock Mounting Bolts Installation Note
1. Assemble the steering lock component to the steering shaft.
2. Verify that the lock operates correctly.
3. Install new steering lock mounting bolts.
4. Tighten the bolts until the heads break off.
DBR614ZWB602
Steering Shaft Installation Note
Caution
• Do not apply a shock in the axial direction of the shaft.
1. Lock the tilt lever. (Equiped with tilt mechanism)

2. Tighten nut A.
3. Tighten bolt B.
Tightening torque
15.7-22.5 N·m {1.60-2.29 kgf·m, 11.6-16.5
ft.lbf}
DBR614ZWB002
Steering Wheel Installation Note

1. Make sure the wheels in the straight-ahead position, and install the steering wheel.
06-14-8
POWER STEERING
STEERING SHAFT INSPECTION
dcf06143210Ow01
1. Inspect the following.

(1) Column bearing for damage
(2) Steering shaft length
Steering shaft length

789.9-792.9 mm {31.1 0-31.22 in}
(3) Dust boot damage

• Replace the steering shaft component as
necessary.
DBR614ZWB504
2. Inspect the tilt operation. (Equiped with tilt

mechanism)
(1) Verify that the tilt lever moves smoothly from
unlock position to lock position.
(2) Verify that the steering shaft is fixed firmly
when the tilt lever is locked.
• Replace the steering shaft component as
necessary.
l
UNLOCKED
TILT LEVER
DBR614ZW555
06-14-9
POWER STEERING
STEERING GEAR AND LINKAGE REMOVAL/INSTALLATION
dcf061432960w01
Caution
place where the sensor will not be pulled by mistake while servicing the vehicle.
1. Remove the front ABS wheel-speed sensor. (with 4W-ABS) (See 04-13B-7 FRONT ABS WHEEL-SPEED
SENSOR REMOVAL/INSTALLATION [4W-ABS (4x2 (EXCEPT Hi-Rider»].) (See 04-13B-8 FRONT ABS
WHEEL-SPEED SENSOR REMOVAL/INSTALLATION [4W-ABS (Hi-Rider, 4x4)].)
4. After installation, adjust the total toe-in. (See 02-11-3 FRONT WHEEL ALIGNMENT [4x2].) (See 02-11-5 .
FRONT WHEEL ALIGNMENT [4x4].)
~
@~
51.5-68.6
{5.25-7.00,
~@~
38.0-50.5} <D
~Al
-'~ 44.1-58.8
{4.50-6.00,
~
1iI 32.5-43.3}
r -----®
@--®t
78.4-156.8
~ / {7.99-15.99,57.82-115.6}
mD
Al 3
-
~@)~ 8 1iI~
A ?
43.5-64.7
0 a~ ~~~~;~~' ®
44.1-58.8
{4.50-6.00,
1 32.5-43.3}
44.1-58.8
~ 7
{4.50-6.00,
32.5-43.3}
«o,!". iii
{4.50-6.00,
32.5-43.3}
DBR614ZWB502
1 Cotter pin 8 Bushing

2 Locknut 9 Washer
3 Ball joint 10 Bolt, Nut, washer
(See 06-14-11 Ball Joint, Idler Arm, Steering Gear 11 Idler arm bracket
and Pitman Arm Removal Note.)
12 Pressure pipe
4 Tie rod
13 Return pipe
5 Locknut
14 Bolt
6 Center link
15 Bolt, Nut, Washer
7 Idler arm
(See 06-14-11 Ball Joint, Idler Arm, Steering Gear 16 Steering gear and pitman arm
(See 06-14-11 Ball Joint, Idler Arm, Steering Gear
06-14-10
POWER STEERING
Ball Joint, Idler Arm, Steering Gear and Pitman Arm Removal Note
1. Remove the ball joint from the knuckle and center ,-------------------:;;----,
link, the idler arm from the center link, and
steering gear and pitman arm from the center link " I
using the SST.
STEERING GEAR AND LINKAGE DISASSEMBLY/ASSEMBLY

dcf061432960w02

3. After assembly, adjust the steering gear backlash. (See 06-14-13 Steering Gear Backlash Adjustment.)
f-----{4
<O>----®1iI
@--------@ iii -~o
{5.7-6.5,42-47}
~ ~ ®1lI1
~ ~'----®
@ iii
~ . ··147-167
------cD {15.Q-17.0,
10B-123}
DBR614ZWB503
1 Nut 4 Sector shaft

2 Pitman arm (See 06-14-12 Locknut, Sector Shaft Disassembly
(See 06-14-12 Pitman Arm Disassembly Note.) Note.)
3 Locknut 5 Side cover
(See 06-14-12 Locknut, Sector Shaft Disassembly 6 O-ring
Note.) 7 Back up ring
8 Y packing
06-14-11
POWER STEERING
9 Oil seal 13 O-ring

10 Y packing 14 Seal ring
11 Back up ring 15 Gear housing
12 Valve and piston component
(See 06-14-12 Valve and Piston Component
Assembly Note.)
Pitman Arm Disassembly Note

1. Separate the pitman arm from the steering gear
using the SST.
DBR614ZWB008
Locknut, Sector Shaft Disassembly Note

1. Loosen the locknut.
2. Remove the side cover attaching bolts.
3. Set the sector shaft in the middle position.
4. Tap the sector shaft lower end using a plastic hammer to loosen the sector shaft.
5. Lift and remove the sector shaft with the locknut ,------------;-----------,
and the side cover from the gear housing.
DBR614ZWB009
Valve and Piston Component Assembly Note
Caution
• Do not scratch the seal ring and a-ring on the piston against the entrance to the housing
• Insert the piston by slightly turning to the left and right so as not to create flection at the a-ring
and seal ring.
1. Insert the valve and piston component to the gear

housing.
06-14--12
POWER STEERING
2. Inspect the worm shaft preload using the SST.
Steering gear worm shaft preload

0.64-1.23 N·m {6.6-12.5 kgf·cm, 5.7-10.8
in.lbf}
[Pull scale reading: 6.4-12.3 N {0.66-1.25
kgf, 1.44-2.76 Ibf}]
• If not within specification, replace the valve and

piston component.
DBR614ZWB898
STEERING GEAR AND LINKAGE INSPECTION

dcf06143296Ow03
Tie-rod End Inspection

1. Inspect the tie-rod end for damage and excessive play.
• If there are any cracks, replace the tie-rod end.
2. Inspect the boot for cracks.
• If there is any malfunction, replace the tie-rod end boot.
• If there is any malfunction, replace the tie-rod end boot.
4. Measure the rotational torque of the tie-rod end ,--------------------,
using the SST and a pull scale.
• If not within the specification, replace the tie-
rod end.
Tie-rod end rotational torque

0.49-1.18 N·m {5-12 kgf·cm, 4.4-10.4
in·lbf}
[Pull scale reading: 4.9-11.8 N·m {0.5-1.2
kgf,1.11-2.65Ibf}]
A6E6316W100
Steering Gear Backlash Adjustment
Caution
• Adjust the backlash while keeping the steering gear in the center position. Otherwise, the
backlash becomes excessively small and gears,m_a_y_b_e_d_a_m_ag_e_d_._ _-=________-----,
1. Turn the adjusting screw to adjust steering gear
backlash.
m
Steering gear backlash
o mm {O in}
06-14-13
POWER STEERING
POWER STEERING OIL PUMP REMOVAUINSTALLATION
dcf061432650w01
1. Remove the battery and battery tray. (See 01-17~2 BATTERY REMOVAL/INSTALLATION.)
2. Remove the clip shown in the figure.
CLIP
DBR614ZWB020
V~29.4-44.1
{3.0D-4.49,21.7-32.5}
£i~---..
-~
-- \
18.6-25.5
{1.90-2.60,
13.8-18.8}
------....,~
18.6-25.5
{1.90-2.60, 4
13.8-18.8}
N·m {kgf·m, ft·lbl}
DBR614ZWB121
1 Bracket (except WL-3) 4 Bolt and nut

2 Pressure pipe 5 Power steering oil pump
3 Return hose 6 O-ring
06-14-14
POWER STEERING
POWER STEERING OIL PUMP DISASSEMBLY/ASSEMBLY
dcf061432650w02
Note
• The following procedure is for replacement of the O-ring and oil seal only. Replace the pump component if
other repairs are necessary. .

3. After installing the PIS pump. flush the power steering system according to the following procedures.
(1) Add ATF until it reaches the MAX level of the PIS fluid tank.
(2) Start the engine and turn the steering wheel fully to the left and right several times to circulate the ATE
• If the fluid level is dropped. add ATF
(3) Drain the ATE
(4) Add the new ATF to the MAX level of the PIS fluid tank, and repeat Step (1) and (2) a few times.
mJ
2
22-26
~ {2.2-2.6, 16-19}
7.S-12N·m
{S0-122 kgf·cm,
69.0-106 in·lbf}
~
II
7.S-11.S N·m
{S0-123 kgf.cm,
70-105 in·lbf}
1
• {5.0-7.0,
36-50}

DBR6HZW901
1 Stud 3 Suction pipe

(See 06-14-16 Stud Disassembly Note.) 4 O-ring
(See 06-14-19 Stud Assembly Note.)
5 Connector
2 Power steering oil pump component
(See 06-14-16 Power Steering Oil Pump
6 O-ring
Component Disassembly Note.) 7 Control valve
06-14-15
POWER STEERING
8 Spring 14 Side plate

9 Rear pump body (See 06-14-18 Side Plate Assembly Note.)
(See 06-14-18 Rear Pump Body Assembly Note.) 15 a-rings
10 a-ring 16 Front pump body
11 Cam ring 17 Gear shaft component
(See 06-14-18 Rotor, Cam Ring, Vane, Assembly (See 06-14-16 Gear Shaft Component Disassembly
Note.) Note.)
12 Rotor (See 06-14-17 Gear Shaft Component Assembly
(See 06-14-18 Rotor, Cam Ring, Vane, Assembly Note.)
Note.) 18 Oil seal
13 Vane (See 06-14-17 Oil Seal Disassembly Note.)
(See 06-14-18 Rotor, Cam Ring, Vane, Assembly (See 06-14-17 Oil Seal Assembly Note.)
Note.)
Stud Disassembly Note

1. Tighten 2 nuts against each other on the stud,
and then remove it.
DBR614ZWB201
Power Steering Oil Pump Component Disassembly Note

1. Secure the power steering oil pump using the
SST.
Caution
• Use the SST to prevent damage to the
pump when securing it in a vise.
DBR614ZWB202
Gear Shaft Component Disassembly Note

1. Remove the snap ring to front body shown in the
figure.
SNAP RING
DBR614ZWB888
06-14-16
POWER STEERING
2. Tap the gear shaft from the shaft side using a
plastic hammer to remove it.

1. Tap the oil seal out using a flathead screwdriver.
Caution
• To prevent damaging the power steering
oil pump body when tapping it out, wrap
a clean rag on the end of the flathead
screwdriver. If the power steering oil
pump body is damaged, replace it
together with the power steering oil
pump component.
DBR614ZWB204

1. Press fit the oil seal using a proper pipe.
Caution
• Install it so that the side with narrow
groove points outwards.
~------------------------------~D~BR~6-14~ZW~B~20~,1!J!II
Gear Shaft Component Assembly Note
1. Set a proper pipe into the gear depression and
press fit the gear shaft.
DBR614ZWB207
06-14-17
POWER STEERING
2. Install the snap ring to front body shown in the
figure.
SNAP RING
DBR614ZWB888
Side Plate Assembly Note

1. Install the side plate in the front pump body
shown in the figure
DBR614ZWB500
Rotor, Cam Ring, Vane, Assembly Note

1. Install the rotor in the front pump body shown in the figure.
2. Install the cam ring in the front pump body shown r------------------------,
in the figure.
3. Install the vane in the rotor.
DBR614ZWB206
Rear Pump Body Assembly Note

1. Install a new O-ring and the side plate to the front body.
2. Position the side plate using the rear pump body.
3. Install the rear body to the rear pump body.
DBR614ZWB208
06-14-18
POWER STEERING
Stud Assembly Note
1. Tighten 2 nuts against each other on the stud,
and then install it so that the stud projection is
within the following specification.
DBR614ZWB201
06-14-19
TECHNICAL DATA

STEERING TECHNICAL DATA . ....... 06-50-1
STEERING TECHNICAL DATA

dcf06500000Ow01
Item Specification
Steering wheel play 0-30 mm {0-U8 in}
Steering wheel effort 7.8 N·m {80 kgf·cm, 58 in·lbf} max.
Steering shaft length 789.9-792.9 mm {31.10-31.22 in}
0.64-1.23 N·m {6.6-12.5 kgf·cm, 5.7-10.8 in·lbf}
Steering gear worm shaft preload
[Pull scale reading: 6.4-12.3 N {O.66-1.25 kgf, 1.44-2.76Ibt}]
0.49-1.18 N·m {5-12 kgf·cm, 4.4-10.4 in·lbt}
Tie-rod end rotational torque
[Pull scale reading: 4.9-11.8 N·m {0.5-1.2 kgf, 1.11-2.65 Ibt}]
Steering gear backlash Omm
Power steering fluid type ATF M-III or equivalent (e.g. Dexron®lI)
Power steering fluid capacity (approx. quantity) 1.1 L {1.2 US qt, 1.0 Imp qt}
Oil pump fluid pressure 9.3-9.8 MPa {94.8-99.9 kgf/cm 2 , 1348-1421 psi}
Gear housing fluid pressure 9.30-9.79 MPa {94.8-99.8 kgf/cm 2 , 1348-1419psi}
06-50-1
SERVICE TOOLS
06-60 SERVICE TOOLS

STEERING SST .................... 06-60-1
STEERING SST
dcf06600000Ow01
491232670B 49 H002 671 49 G032 3A4A
Power steering Adapter ~C'=:::::::=IHJ:I' Power steering

gauge set flirT gauge adapter
~ iCfDI set
49 T028 3AO 49 U032 3AO 490180510B
Ball joint puller Pitman arm Preload

set measuring
attachment
49 F032 301 49 B032 304 49 G032 354
Power Steering Adapter Adjusting

Pump Hanger Wrench
06-60-1
AIR CONDITIONING (HVAC) 07SECTION
SYMPTOM CONTROL SYSTEM ......... 07-40

TROUBLESHOOTING ...... 07-03 TECHNICAL DATA .......... 07-50
REFRIGERANT SYSTEM .... 07-10 SERVICE TOOLS ........... 07-60
BASIC SYSTEM ............ 07-11
07-03 SYMPTOM TROUBLESHOOTING

FOREWORD ..................•..• 07-03-1 NO.3 NO TEMPERATURE CONTROL
TROUBLESHOOTING INDEX ......... 07-03-1 WITH CLIMATE CONTROL UNIT ..... 07-03-3
NO.1 INSUFFICIENT AIR (OR NO AIR) NO.4 AIR FROM VENTS COLD
BLOWN FROM VENTS ....•••..•... 07-03-1 ENOUGH ••..••...•.....•....••.. 07-03-4
NO.2 AMOUNT OF AIR BLOWN FROM NO.5 NO COOL AIR .......•.•..••... 07-03-6
VENTS DOES NOT CHANGE .••..•.. 07-03-2 NO.6 NOISE WHILE OPERATING AlC
SYSTEM •..•••...........•..•.•.. 07-03-8
FOREWORD
dcf07030000Ow01
• The areas for inspection (steps) are given according to various circuit malfunctions. Use the following chart to
verify the symptoms of the trouble in order to diagnose the appropriate area.
TROUBLESHOOTING INDEX
dcf070300000w02
No. TROUBLESHOOTING ITEM DESCRIPTION

1 Insufficient air (or no air) blown from vents. • Problem with each vent and/or duct.
2 Amount of air blown from vents does not change. • Malfunction in blower system.
3 No temperature control with climate control unit. • Malfunction in air outlet duct and/or climate control
unit air mix system.
4 Air from vents not cold enough. • Magnetic clutch operates but Ale system
malfunctions.
5 No cool air. • Magnetic clutch does not operate.
6 Noise while operating Ale system. • Noise from magnetic clutch, Ale compressor, hose
or refrigerant line.
NO.1 INSUFFICIENT AIR (OR NO AIR) BLOWN FROM VENTS
1 Insufficient air (or no air) blown from vents.

DESCRIPTION • Problem with each vent and/or duct.
• Malfunction in VENT mode system (Steps 1-4)
POSSIBLE
• Malfunction in HEAT mode system (Step 5)
CAUSE
• Malfunction in DEFROSTER mode system (Steps 6-8)
Step Inspection Inspection item (s)
1 INSPECT TO SEE WHETHER MALFUNCTION Yes Go to Step 4.
IS IN VENT MODE OR OTHER MODES No Go to next step.
• Does air blowout when in VENT mode?
2 INSPECT VENT Yes Remove obstruction, then go to Step 8.
• Is vent clogged? No Go to the next step.
3 . VERIFY THAT DUCT IN DASHBOARD IS Yes Inspect duct for clogging, deformity and air leakage, then go
INSTALLED to Step 8.
• Is duct in dashboard properly installed? No Install duct securely in the proper position, then go to Step
8.
07-03-1
SYMPTOM TROUBLESHOOTING

4 INSPECT TO SEE WHETHER MALFUNCTION Yes Go to the next step.
IS IN HEAT MODE OR DEFROSTER MODE No Inspect vent for clogging, then go to Step 8.
• Does air blowout when in HEAT mode?
5 INSPECT DEFROSTER MODE Yes Operation is normal. Recheck malfunction symptoms.
• Does air blowout when in DEFROSTER No Go to the next step.
mode?
6 INSPECT VENT Yes Remove obstruction, then go to Step 8.
• Is vent clogged? No Go to the next step.
7 VERIFY THAT DEFROSTER DUCT IS Yes Inspect duct for clogging, deformity, and air leakage, then
INSTALLED go to the next step.
• Is defroster duct properly installed? No Install duct securely in proper position, then go to the next
step.
8 CONFIRM THAT MALFUNCTION SYMPTOMS Yes Troubleshooting completed.
DO NOT RECUR AFTER REPAIR Explain repairs to customer.
• Does air blowout? No Recheck malfunction symptoms, then repeat from Step 1 if
malfunction recurs.
NO.2 AMOUNT OF AIR BLOWN FROM VENTS DOES NOT CHANGE

dcf070300000w04
2 Amount of air blown from vents does not change.

DESCRIPTION • Malfunction in blower system.
POSSIBLE • Blower relay, blower motor, resistor, fan switch malfunction (Step 1)
CAUSE • Blower unit malfunction (Steps 2-4)
1 INSPECT BLOWER SYSTEM Yes Go to the next step.
• Inspect the following systems and electrical No Repair or replace malfunctioning part, then go to Step 5.
parts.
- Blower relay
- Blower motor
- Resistor
- Fan switch
- Related wiring harnesses
• Are they normal?
2 CHECK TO SEE WHETHER MALFUNCTION Yes Go to Step 4.
IS IN BLOWER UNIT OR ELSEWHERE No Go to the next step.
• Turn engine switch to ON position.
• Turn fan switch on.
• Recirculate air inside vehicle.
• Does fan in blower unit rotate smoothly?
3 INSPECT BLOWER UNIT Yes Go to the next step.
• Inspect fan in blower unit. No Remove obstruction, repair or replace fan and blower unit
- Is fan free of interference from blower unit case, then go to Step 5.
case?
- Is fan free of foreign material and
obstructions?
• Is fan normal?
4 INSPECT BLOWER UNIT INTAKE VENT Yes Remove obstruction, then go to the next step.
• Is blower unit intake vent clogged? No Inspect if there are any obstructions in passage _between
blower unit and air outlet duct, then go to the next step.
5 VERIFY THAT MALFUNCTION SYMPTOM Yes Troubleshooting completed.
OCCURS AFTER REPAIR Explain repairs to customer.
• Does air blowout? No Recheck malfunction symptoms, then repeat from Step 1 if
malfunction recurs.
07-03-2
NO.3 NO TEMPERATURE CONTROL WITH CLIMATE CONTROL UNIT
dcf070300000w05
3 No temperature control with climate control unit.

DESCRIPTION • Malfunction in air outlet duct and/or climate control unit air mix system.
• Air outlet duct air mix link, air mix crank, air mix rod, air mix wire, wire clamp malfunction (Steps 2, 3)
POSSIBLE • Climate control unit rack-and-pinion, air mix wire malfunction (Step 4)
CAUSE • Air outlet duct air mix door malfunction (Steps 5, 6)
• Heater piping malfunction (Step 7)
1 INSPECT COOLANT TEMPERATURE Yes Go to the next step.
• Is coolant sufficiently warmed up? No Warm engine up, then go to Step 8.
2 INSPECT AIR OUTLET DUCT AIR MIX Yes Go to the next step.
SYSTEM No Apply grease or install links, cranks, and rods securely in
• Inspect air outlet duct air mix links, air mix their proper positions, repair or replace wire clamp, then go
cranks, air mix rods or wire clamp. to Step 8.
- Is there grease on links and cranks?
- Are links, cranks, and rods. securely
installed in their proper positions?
- Is wire clamp free of deformation?
• Are above items normal?
3 VERIFY THAT AIR MIX WIRE FROM AIR Yes Go to the next step.
OUTLET DUCT IS POSITIONED SECURELY No Adjust air mix wire or install securely in correct position, then
AND CORRECTLY (IF AVAILABLE) go to Step 8.
• Is air mix wire securely installed in the
correct position in relation to air outlet duct
air mix links?
4 INSPECT CLIMATE CONTROL UNIT Yes Go to the next step.
• Inspect climate control unit as follows. No Properly engage bevel gear or install air mix wire in correct
- Is bevel gear set properly engaged? position, repair or replace wire clamp, then go to Step 8.
- Is air mix wire properly installed in correct
position in relation to bevel gear?
- Is wire clamp free of deformation?
• Are above items okay?
5 INSPECT AIR OUTLET DUCT Yes Remove obstruction, then go to Step 8.
• Is there any foreign material or obstruction in No Go to the next step.
air outlet duct air mix doors?
6 INSPECT AIR OUTLET DUCT AIR MIX Yes Inspect air mix door for cracks or damage, then go to the
DOORS next step.
• Is air outlet duct air mix door securely and No Install air mix door securely in proper position, then go to the
properly installed? next step.
7 INSPECT HEATER LINES Yes Operation is normal. Recheck malfunction symptoms.
• Inspect heater lines. No If heater piping connections is loosed, tighten connections
- Is heater piping free of damage and with specified torque.
cracks? Repair or replace heater piping, then go to the next step.
- Are heater piping connections free of
engine coolant leakage?
- Are heater piping connections securely
tightened?
- Are heater piping installation points on air
outlet duct free of engine coolant
leakage?
• Does unit operate in every temperature No Recheck malfunction symptoms, then repeat from Step 1 if
setting? malfunction recurs.
07-03-3
NO.4 AIR FROM VENTS COLD ENOUGH
dcf070300000w06
4 Air from vents not cold enough.

DESCRIPTION • Magnetic clutch operates but AlC system malfunctions.
• Drive belt malfunction (Step 2)
• Malfunction in blower unit or condenser (Steps 4, 5)
POSSIBLE • Malfunction in receiver/drier or expansion valve (valve closes too much) (Steps 8, 9)
CAUSE • Malfunction in refrigerant lines (Steps 10, 11)
• AlC compressor system malfunction, insufficient compressor oil (Steps 15, 16)
• Over filling of compressor oil, malfunction in expansion valve or air outlet duct air mix link system (Steps
17-19)
1 INSPECT DRIVE BELT Yes Go to the next step.
• Inspect drive belt. No Adjust or replace drive belt, then go to Step 20.
(See 01-10A-3 DRIVE BELT INSPECTION
[WL-3].) (See 01-10B-3 DRIVE BELT
• Is it normal?
2 INSPECT REFRIGERANT SYSTEM Yes Operation is normal. (Recheck malfunction symptoms.)
PERFORMANCE No Go to the next step.
• Perform refrigerant system performance test.
(See 07-10-2 REFRIGERANT SYSTEM
PERFORMANCE TEST.)
• Is operation normal?
3 CHECK TO SEE WHETHER MALFUNCTION Yes Go to the next step.
IS IN BLOWER UNIT INTAKE AND No Go to Step 6.
CONDENSER OR ELSEWHERE
• Are refrigerant high-pressure and low-
pressure values both high?
4 INSPECT BLOWER UNIT INTAKE Yes Remove obstruction, then go to Step 20. (If air does not
• Is blower unit intake clogged? reach evaporator within cooling unit, heat exchange does
not occur and refrigerant pressure becomes high.
Therefore, removal of obstruction is necessary.)
5 INSPECT CONDENSER Yes Adjust refrigerant to specified amount, then go to Step 20.
• Inspect condenser. (Excessive amount of refrigerant.)
(See 07-11-8 CONDENSER INSPECTION.) No Replace condenser, or repair and clean condenser fins,
• Is it normal? then go to Step 20.
IS IN EXPANSION VALVE, RECEIVER/DRIER No Go to Step 14.
AND REFRIGERANT LINES OR ELSEWHERE
• Are refrigerant high-pressure and low-
pressure values low?
IS IN EXPANSION VALVE AND RECEIVER! No Go to Step 10.
DRIER OR ELSEWHERE
• Immediately after AlC compressor operates,
does refrigerant high-pressure value
momentarily rise to correct value, then fall
and stay below it? (Is there negative
pressure on low-pressure side?)
IS IN EXPANSION VALVE OR RECEIVER! No Replace condenser and vacuum refrigerant line 30 min or
DRIER more by vacuum pump, add refrigerant to specified level,
• Turn AlC switch off and let air conditioner then go to Step 20. (Since water has intermixed in receiver/
stop for 10 min. drier and it is saturated, replacement is necessary.)
• Start engine.
• Turn both AlC switch and fan switch on.
• Does malfunction occur after AlC
compressor turns on?
07-03-4

9 VERIFY THAT EXPANSION VALVE HEAT- Yes Replace expansion valve, then go to Step 20. (Since valve
SENSING TUBE WITHIN COOLING UNIT IS closes too much, replacement is necessary.)
POSITIONED SECURELY AND CORRECTLY No Install heat-sensing tube securely in proper position, then go
• Is expansion valve heat-sensing tube within to Step 20.
cooling unit securely installed in proper
position?
10 INSPECT REFRIGERANT LINES Yes Go to the next step.
• Inspect refrigerant lines. No If piping or AlC component (s) are damaged or cracked,
- Is piping free of damage and cracks? replace them.
- Are piping connections free of oil grime? Then go to Step 20.
(Visual inspection) If there is no damage, go to Step 13.
- Are piping connections free of gas
leakage?
- Are piping installation points on
condenser free of gas leakage?
- Are piping installation points on receiver/
drier free of gas leakage?
- Are piping installation points on AlC
compressor free of gas leakage?
- Are piping installation points on cooling
unit free of gas leakage?
- Perform gas leak inspection using gas
leak tester.
11 INSPECT EVAPORATOR PIPING Yes If the vane makes a noise, add 10 ml {10 ee, 0.34 fl oz} of
CONNECTIONS IN COOLING UNIT FOR GAS compressor oil to the AlC compressor. Verify that the noise
LEAKAGE is no longer heard.
• Are piping connections for evaporator in Adjust refrigerant to specified amount, then go to Step 20.
cooling unit free of gas leakage? No If piping is damaged or cracked, replace it.
Then go to Step 20.
If there is no damage,go to the next step.
12 INSPECT EVAPORATOR PIPING Yes Tighten connections with specified torque, adjust both
CONNECTIONS IN COOLING UNIT FOR compressor oil and refrigerant to specified amount, then go
LOOSE to Step 20.
• Are piping connections for evaporator in No If the vane makes a noise, add 10 ml {10 ee, 0.34 fl oz} of
cooling unit loose? compressor oil to the AlC compressor. Verify that the noise
is no longer heard.
Replace a-ring on piping, adjust refrigerant to specified
amount, then go to Step 20.
13 INSPECT PIPING CONNECTIONS FOR Yes Tighten connections with specified torque, adjust both
LOOSE compressor oil and refrigerant to specified amount, then go
• Are piping connections loose? to Step 20.
No If the vane makes a noise, add 10 ml {10 ee, 0.34 fl oz} of
compressor oil to the AlC compressor. Verify that the noise
is no longer heard.
Replace a-ring on piping, adjust refrigerant to specified
amount, then go to Step 20.
14 CHECK TO SEE WHETHER MALFUNCTION Yes Go to the next step. (Pressure hardly increases.)
IS IN EXPANSION VALVE, AIR MIX No Go to Step 17.
ACTUATOR AND COMPRESSOR OIL OR
ELSEWHERE
• Does refrigerant high-pressure value hardly
increase?
15 CHECK TO SEE WHETHER MALFUNCTION Yes Return to Step 3.
IS IN COMPRESSOR OIL AMOUNT AND AlC No Go to the next step.
COMPRESSOR OR ELSEWHERE
• When engine is racing, does high-pressure
value increase?
16 CHECK TO SEE WHETHER MALFUNCTION Yes Troubleshooting completed. (Explain to customer that cause
IS IN COMPRESSOR OIL AMOUNT OR AlC was insufficient compressor oil.)
COMPRESSOR No Replace AlC compressor, then go to Step 20. (Cause is
• After compressor oil is replenished each 10 defective AlC compressor.)
ml {10 ee, 0.34 fl oz}, does high-pressure
value increase?
17 CHECK TO SEE WHETHER MALFUNCTION Yes Go to Step 19.
IS IN EXPANSION VALVE OR ELSEWHERE No Go to the next step.
• Is only refrigerant low-pressure value high?
07-03-5

18 VERIFY THAT AIR MIX IS INSTALLED Yes Set fan switch to 4th position.
SECURELY AND PROPERLY Turn AlC switch on.
• Are air outlet duct air mix links, air mix Set FRESH mode.
cranks, and air mix rods securely and Set temperature control to MAX COLD.
properly installed? Set VENT mode.
(1 )Start and run the engine at 1,500 rpm for 10 min.
(2)Run the engine at idle for 1 min.
(3)Within 12 s, idle -? 4,000 rpm -? idle. Perform cycle 5
times.
(4) Run the engine at idle for 30 s.
(5)Drain the compressor oil completely from the AlC
compressor and verify the amount.
• If there is approx. 90 ml {90 cc, 3.0 fl oz} of
compressor oil, go to Step 20.
• If there is more than 90 ml {90 cc, 3.0 fl oz} of
compressor oil, remove surplus oil and fill AlC
compressor with 90 ml {90 cc, 3.0 fl oz} of
compressor oil. Repeat Steps (1) to (5).
(Cause is excessive amount of compressor oil.)
No Repair or install links, cranks and rods securely in proper
position, then go to Step 20.
19 VERIFY THAT EXPANSION VALVE HEAT- Yes Replace expansion valve, then go to the next step. (Since
SENSING TUBE WITHIN COOLING UNIT IS valve opens too much, replacement is necessary.)
POSITIONED SECURELY AND CORRECTLY No Install heat-sensing tube securely in proper position, then go
• Is expansion valve heat-sensing tube within to the next step.
cooling unit securely installed in proper
position?
• Does cool air blowout? (Are results of No Recheck malfunction symptoms, then repeat from Step 1 if
refrigerant system performance test malfunction recurs.
normal?)
NO.5 NO COOL AIR

dcf070300000w07
5 No cool air
DESCRIPTION • Magnetic clutch does not operate.
• Malfunction in PCM AlC cut control system (Step 3)
• Malfunction in climate control unit (Step 4)
• Malfunction in refrigerant pressure switch (Steps 5, 7-9)
POSSIBLE • Malfunction in PCM (AiC signal) (Step 6)
CAUSE • Malfunction in PCM (IG1 signal) (Steps 10,11)
• Malfunction in AlC compressor (Step 12)
• Malfunction in AlC relay (Steps 13-15)
• Malfunction in evaporator temperature sensor (Step 16)
• When performing an asterisked (*) troubleshooting inspection, shake the wiring harness and connectors while
performing the inspection to discover whether poor contact points are the cause of any intermittent
malfunctions. If there is a problem, check to make sure connectors, terminals and wiring harnesses are
connected correctly and undamaged.
1 INSPECT AIR BLOW OUT Yes Go to the next step.
• Does air blowout? No Go to Step 1 of troubleshooting index No.1.
2 INSPECT AlC COMPRESSOR OPERATION Yes Go to Step 1 of troubleshooting index No.4.
• Start engine. No Go to the next step.
• Turn AlC switch and fan switch on.
• Does AlC compressor operate?
3 INSPECT FOR DTC IN PCM Yes Go to appropriate inspection procedure.
• Inspect for DTCs related to the PCM on- No Go to the next step.
board diagnostic system.
• Are any DTCs displayed?
07-03-6

4 INSPECT TO SEE WHETHER MALFUNCTION Yes Replace climate control unit, then go to Step 17.
IS IN CLIMATE CONTROL UNIT OR No Release short, then go to the next step.
ELSEWHERE
• Does cool air blowout when terminal 38 of
climate control unit connector (3-pin, AlC
signal) is grounded?
5* INSPECT TO SEE WHETHER MALFUNCTION Yes Go to Step 7.
IS IN AlC SIGNAL CIRCUIT (BETWEEN No Go to the next step.
REFRIGERANT PRESSURE SWITCH AND
PCM) OR ELSEWHERE
• Test voltage at following terminal of
refrigerant pressure switch. .
- Terminal 8 (AiC signal)
• Is voltage approx. 12 V?
6* INSPECT TO SEE WHETHER MALFUNCTION Yes Repair wiring harness between PCM and refrigerant
(LACK OF CONTINUITY) IS IN WIRING pressure switch, then go to Step 17.
HARNESS (BETWEEN REFRIGERANT No Inspect PCM, then go to Step 17.
PRESSURE SWITCH AND PCM) OR PCM
• Test voltage at AlC signal terminal of PCM.
7 INSPECT TO SEE WHETHER MALFUNCTION Yes Go to Step 9.
IS IN REFRIGERANT PRESSURE SWITCH, No Go to the next step.
REFRIGERANT AMOUNT, OR ELSEWHERE
• Does cool air blowout when terminals A and
8 of refrigerant pressure switch connector
are shorted?
8* INSPECT TO SEE WHETHER MALFUNCTION Yes Go to Step 10.
IS IN WIRING HARNESS (BETWEEN No Repair wiring harness between refrigerant pressure switch
REFRIGERANT PRESSURE SWITCH AND and climate control unit, then go to Step 17.
CLIMATE CONTROL UNIT) OR ELSEWHERE
• Test voltage at following terminal of climate
control unit. (3-pin)
- Terminal 38 (3-pin, AlC signal)
9 INSPECT TO SEE WHETHER MALFUNCTION Yes If refrigerant amount is empty, replace condenser, vacuum
IS IN REFRIGERANT PRESSURE SWITCH OR refrigerant line 30 min or more by vacuum pump, and add
REFRIGERANT AMOUNT refrigerant to specified level, then go to Step 17.
• Inspect refrigerant pressure switch. No Replace refrigerant pressure switch, then go to Step 17.
• Is it normal?
10 INSPECT TO SEE WHETHER MALFUNCTION Yes Release short, then go to the next step.
(LACK OF CONTINUITY) IS IN AlC CONTROL No Go to Step 12.
SIGNAL CIRCUIT (BETWEEN AlC RELAY
AND PCM) OR ELSEWHERE
• Does cool air blowout when terminal E of AI
C relay connector (AiC control signal) is
grounded?
11* INSPECT TO SEE WHETHER MALFUNCTION Yes Inspect PCM, then go to Step 17.
(LACK OF CONTINUITY) IS IN PCM OR No Repair wiring harness between AlC relay and PCM, then go
WIRING HARNESS (BETWEEN AlC RELAY to Step 17.
AND PCM)
• Test voltage at the AlC relay control signal
terminal of PCM.
12* INSPECT TO SEE WHETHER MALFUNCTION Yes Inspect magnetic clutch, then go to Step 17.
IS IN MAGNETIC CLUTCH OR ELSEWHERE No Go to the next step.
• Test voltage at the following terminal of
magnetic clutch.
- Terminal A (magnetic clutch operation
signal)
13 INSPECT FUSE Yes Go to the next step.
• Are AlC relay power supply fuses normal? NO Replace fuse, then go to Step 17. If fuse burns out
immediately, go to the next step.
07-03-7

14 INSPECT WIRING HARNESS BETWEEN Yes Go to the next step.
FUSE BLOCK AND AlC RELAY FOR LACK No Repair wiring harness between fuse block and AlC relay,
OF CONTINUITY then go to Step 17.
• Test voltages at following terminals of AlC
relay.
- Terminal A (AiC relay control signal)
- Terminal C (AiC control signal) ,
• Are voltages approx. 12 V?
15 INSPECT TO SEE WHETHER MALFUNCTION Yes Inspect wiring harness between AlC relay and magnetic
IS IN AlC RELAY OR WIRING HARNESS clutch.
(BETWEEN AlC RELAY AND MAGNETIC • If above wiring harness is normal, go to the next step.
CLUTCH) AND EVAPORATOR • If above wiring harness malfunctions, repair wiring
TEMPERATURE SENSOR harness, then go to Step 17.
• Test voltage at the following terminal of AlC No Replace AlC relay, then go to Step 17.
relay.
- Terminal D (magnetic clutch operation
signal)
16 INSPECT EVAPORATOR TEMPERATURE Yes Go to the next step.
SENSOR No Replace evaporator temperature sensor, then go to the next
• Inspect evaporator temperature sensor. step.
• Is it normal?
17 CONFIRM THAT MALFUNCTION SYMPTOMS Yes Troubleshooting completed. Explain repairs to customer.
DO NOT RECUR AFTER REPAIR No Recheck malfunction symptoms, then repeat from Step 1 if
• Does cool air blowout? (Are the results of malfunction recurs.
refrigerant system performance test
normal?)
07-03-8
NO.7 NO COOL AIR.[SRSSS]
id070300804804
7 No cool air
DESCRIPTION ? Magnetic clutch does not operate.
? AlC compressor system malfunction (Step 2)
? Incorrect amount of refrigerant (Step 3)
? AlC switch indicator light malfunction (Steps 4-6)
? PCM AlC cut-off control system (WL, WLT-1, WLT-2: Step 18) (G6: Step 7)
POSSIBLE
? PCM (IG1 signal) system malfunction (WL, WLT-1, WLT-2: Steps 8,9) (G6: Step 20)
CAUSE
? Themoswitch, AlC switch malfunction (WL,WLT-1, WLT-2: Steps 11,12,14,15) (G6: Step 10-14)
? PCM (AiC signal) system malfunction (WL, WLT-1, WLT-2: Steps 17) (G6: Step 16, 17)
? Refrigerant pressure switch malfunction (WL, WLT-1, WLT-2: Step 26) (G6: Step19)
? AlC relay malfunction (WL, WLT-1, WLT-2: Steps 22-25) (G6: Step 22-24)
? When performing an asterisked (*) troubleshooting inspection, shake the wiring harness and connectors while
doing the inspection to discover whether poor contact points are the cause of any intermittent malfunctions. If
there is a problem, check to make sure connectors, terminals and wiring harnesses are connected correctly
and undamaged.
1 INSPECT AIR BLOW OUT Yes Go to next step.
? Does air blowout? No Go to Step 1 of troubleshooting indexes No.1, 2.
2 INSPECT AlC COMPRESOR OPERATION Yes Go to Step 1 of troubleshooting index NO.6.
? Start engine. No Go to next step.
? Turn both AlC switch and front fan switch on.
? Does AlC compressor operate?
3 INSPECT REFRIGERANT AMOUNT Yes Go to next step.
? Inspect refrigerant amount. No Add or subtract refrigerant to specified level, then go to Step
? Is it okay? 27.
4 INSPECT AlC SWITCH INDICATOR LIGHT Yes WL or WL-T1, WLT-2: Go to Step 8.
? Does AlC switch indicator light illuminate? G6: Go to Step 7.
No Go to next step.
*5 INSPECT WIRING HARNESS BETWEEN Yes Go to next step.
FUSE BLOCK AND FRONT CLIMATE No Repair wiring harness between fuse block and AlC switch,
CONTROL UNIT FOR CONTINUITY then go to Step 27.
? Turn ignition switch to ON position.
? Remove airflow mode wire and air mix wire
and pull out front climate control unit.
? Test voltage at front climate control unit
terminal C (IG2 signal).
? Is voltage approximately 12 V?
*6 INSPECT AlC SWITCH Yes Inspect wiring harness between AlC switch and resistor,
? Inspect AlC switch. then go to Step 27.
? Is it okay? No Replace AlC switch, then go to Step 27.
7 CHECK FOR DTCS IN PCM Yes Go to appropriate inspection procedure. (The throttle
? Check the DTC for the ON-BOARD position sensor (DTC 0120), which sends the PCM's AlC cut
DIAGNOSTIC (ENGINE CONTROL). off control input signal, may be the cause of the trouble.)
? Are the following DTCs displayed? No Go to Step 10.
-DTC 0120
*8 VERIFY WHETHER MALFUNCTION IS IN Yes Go to next step.
MAGNETIC CLUTCH SYSTEM OR No Go to Step 21.
ELSEWHERE
? Does magnetic clutch operate when AlC
relay connector terminal B (IG2 signal) is
grounded?
*9 VERIFY WHETHER MALFUNCTION IS IN AlC Yes Go to Step 11.
RELAY SYSTEM (COIL-SIDE) OR No Repair wiring harness between AlC relay and PCM, then go
ELSEWHERE to Step 27.
? Turn AlC switch off.
? Test voltage at PCM connector terminal
L(IG1 signal).
07-03-8a

*10 VERIFY WHETHER MALFUNCTION IS IN Yes Go to Step 16.
THEMOSWITCH SYSTEM OR ELSEWHERE No Reconnect refrigerant pressure switch connector, then go to
? Turn ignition switch to LOCK position. next step.
? Remove radiator grille.
? Disconnect refrigerant pressure switch
connector.
? Set front fan switch at first speed.
? Test voltage at the following refrigerant
pressure switch connector terminal B (AiC
signal) on wiring harness side.
? Is voltage approximately 12 V when AlC
switch is off and 0 V when it is on?
*11 VERIFY WHETHER MALFUNCTION IS IN Yes Undo short, then go to next step.
EVAPORATOR TEMPERATURE SENSOR No WL or WL-T1, WLT-2: Undo short, then go to Step 14.
AND WIRING HARNESS (BETWEEN FUSE G6: Undo short, then go to Step 13.
BLOCK AND EVAPORATOR TEMPERATURE
SENSOR FOR CONTINUITY) OR
ELSEWHERE
? Turn ignition switch to LOCK position.
? Remove glove compartment.
? Disconnect evaporator temperature sensor
connector.
? Start engine.
? When evaporator temperature sensor
connector terminals Band C (on wiring
harness side) are shorted, does cool air blow
out?
*12 VERIFY WHETHER MALFUNCTION IS IN Yes Inspect evaporator temperature sensor, then go to Step 27.
EVAPORATOR TEMPERATURE SENSOR OR No Repair wiring harness between fuse block and evaporator
WIRING HARNESS (BETWEEN FUSE BLOCK temperature sensor, then go to Step 27.
AND THEMOSWITCH FOR CONTINUITY)
? Test voltage at evaporator temperature
sensor connector terminal A (IG2 signal).
EVAPORATOR TEMPERATURE SENSOR No Repair wiring harness between refrigerant pressure switch
AND REFRIGERANT PRESSURE SWITCH and evaporator temperature sensor, then go to Step 27.
FOR CONTINUITY
? Turn ignition switch to LOCK position.
? Inspect for continuity between evaporator
temperature sensor connector terminal B (AI
C signal) and refrigerant pressure switch
connector terminal B.
? Is there continuity?
*14 VERIFY WHETHER MALFUNCTION IS IN Yes WL or WL-T1, WLT-2: Go to next step.
EVAPORATOR TEMPERATURE SENSOR G6: Inspect wiring harness between evaporator temperature
AND WIRING HARNESS (BETWEEN sensor and AlC switch, then go to Step 27.
EVAPORATOR TEMPERATURE SENSOR No Inspect AlC switch, then go to Step 27.
AND AlC SWITCH FOR CONTINUITY) OR
ELSEWHERE
? Turn AlC switch ON.
? Turn fan switch ON.
? Test voltage at AlC switch connector terminal
A (AiC signal).
07-03-8b

*15 VERIFY WHETHER MALFUNCTION IS IN Yes Go to Step 17.
EVAPORATOR TEMPERATURE SENSOR No Repair wiring harness between evaporator temperature
AND WIRING HARNESS (BETWEEN sensor and AlC switch, then go to Step 27.
EVAPORATOR TEMPERATURE SENSOR
AND AlC SWITCH FOR CONTINUITY) OR
ELSEWHERE
? Test voltage at evaporator temperature
sensor connector terminal C (AiC signal).
*16 VERIFY WHETHER MALFUNCTION IS IN PCM Yes Go to Step 19.
AND WIRING HARNESS (BETWEEN PCM No Go to next step.
AND REFRIGERANT PRESSURE SWITCH
FOR CONTINUITY) OR ELSEWHERE
? Test voltage at refrigerant pressure switch
connector (on wiring harness side) terminal
A (AiC signal).
*17 VERIFY WHETHER MALFUNCTION IS IN PCM Yes WL or WL-T1, WLT-2: Go to next step.
OR WIRING HARNESS (BETWEEN PCM AND G6: Inspect wiring harness between PCM and refrigerant
REFRIGERANT PRESSURE SWITCH FOR pressure switch, then go to Step 27.
CONTINUITY) No Inspect PCM, then go to Step 27.
? Test voltage at the following PCM connector
terminals (AiC signal).
- Terminal G (WL or WL-T1, WLT-2)
- Terminal Q (G6)
*18 VERIFY WHETHER MALFUNCTION IS IN PCM Yes Repair wiring harness between PCM and evaporator
AND WIRING HARNESS (BETWEEN PCM temperature sensor, then go to Step 27.
AND EVAPORATOR TEMPERATURE No Replace input signal components, then go to Step 27.
SENSOR FOR CONTINUITY) OR
ELSEWHERE
? Inspect the following input signal
components:
- Engine coolant temperature sensor,
including PCM wiring harness (AiC cut-off
control)
? Are they okay?
*19 VERIFY WHETHER MALFUNCTION IS IN Yes Inspect refrigerant pressure switch, then go to Step 27.
REFRIGERANT PRESSURE SWITCH OR No Undo short, reconnect refrigerant pressure switch, then go
ELSEWHERE to next step.
? When the following refrigerant pressure
switch connector terminal A and S (on wiring
harness side) are shorted, does cool air blow
out?
*20 INSPECT TO SEE WHETHER MALFUNCTION Yes Inspect wiring harness between AlC relay and PCM, then
IS IN AlC RELAY OR ELSEWHERE go to Step 27.
? Does magnetic clutch operate when terminal No Go to next step.
S (IG2 signal) of AlC relay connector is
grounded?
*21 VERIFY WHETHER MALFUNCTION IS IN Yes Inspect magnetic clutch, then go to Step 27.
MAGNETIC CLUTCH OR WIRING HARNESS No Go to next step.
(BETWEEN AlC RELAY AND MAGNETIC
CLUTCH FOR CONTINUITY)
? Test voltage at magnetic clutch connector
terminal A (AiC control signal).
22 INSPECT AlC RELAY (SWITCH-SIDE) POWER Yes Go to next step.
SUPPLY FUSE No Inspect for a short to ground on blown fues's circuit. Repair
? Are AlC relay power supply fuses okay? or replace as necessary.
Install appropriate amperage fuse.
07-03-8c

FUSE BLOCK AND AlC RELAY No Repair wiring harness between fuse block and AlC relay,
(SWITCH-SIDE) FOR CONTINUITY then go to Step 27.
? Test voltage at the following AlC relay
connector terminals:
- Terminal A (IG2 signal)
- Terminal C (AIC control signal)
*24 VERIFY WHETHER MALFUNCTION IS IN Yes WL or WL-T1, WLT-2: Go to next step.
MAGNETIC CLUTCH OR WIRING HARNESS G6: Repair wiring harness between AlC relay and magnetic
(BETWEEN AlC RELAY AND MAGNETIC clutch, then go to Step 27.
CLUTCH FOR CONTINUITY) No Inspect AlC relay, then go to Step 27.
? Test voltage at AlC relay connector terminal
D (AIC control signal).
*25 INSPECT WIRING HARNESS BETWEEN Yes. Go to next step.
FUSE BLOCK AND AlC RELAY No Repair wiring harness between AlC relay and refrigerant
(SWITCH-SIDE) FOR CONTINUITY pressure switch, then go to Step 27.
? Test voltage at refrigerant pressure switch
connector (on wiring harness side) terminal
A (AIC control signal)
*26 VERIFY WHETHER MALFUNCTION IS IN Yes Inspect refrigerant pressure switch, then go to next step.
REFRIGERANT PRESSURE SWITCH OR No Repair wiring harness between refrigerant pressure switch
ELSEWHERE and magnetic clutch, then go to next step.
? When refrigerant pressure switch connector
terminal A and B (on wiring harness side) are
shorted, does cool air blowout?
27 VERIFY THAT MALFUNCTION SYMPTOM Yes Troubleshooting completed. Explain repairs to customer.
OCCURS AFTER REPAIR No Recheck malfunction symptoms, then repeat from Step 1 if
? Does cool air blowout? (Is refrigerant system malfunction recurs.
performance test result correct?)
07-03-8d
NO.6 NOISE WHILE OPERATING Ale SYSTEM

dcf070300000w08
6 Noise while operating AlC system.

DESCRIPTION • Noise from magnetic clutch, AlC compressor, hose or refrigerant line.
• Magnetic clutch operation noise (Step 4)
POSSIBLE • AlC compressor vane noise (Steps 5-13)
CAUSE • AlC compressor slippage noise (Steps 14-17)
• Hose or refrigerant line interference noise (Step 18)
1 CHECK AlC COMPRESSOR VANE NOISE Yes Go to Step 5.
• Is there a jingling, popping, beeping, or No Go to the next step.
buzzing sound (AiC compressor vane
noise)?
2 INSPECT AlC COMPRESSOR SLIPPAGE Yes Go to Step 14.
NOISE No Go to the next step.
• Is there a squeaking or whirling sound (AiC
compressor slippage noise)?
3 INSPECT AlC COMPRESSOR Yes Go to Step 18.
INTERFERENCE NOISE No Go to the next step.
• Is there a rattling or vibrating sound
(interference noise)?
4 INSPECT MAGNETIC CLUTCH OPERATION Yes Adjust clearance between pressure plate of magnetic clutch
NOISE and AlC compressor pulley, then go to Step 19.
• Is there a clicking sound (magnetic clutch (See 07-40-4 MAGNETIC CLUTCH ADJUSTMENT.)
operation noise)? No Condition is normal. (Recheck malfunction symptoms.)
5 INSPECT AlC COMPRESSOR NOISE TIME Yes Go to the next step.
• Is noise heard continuously for 3 s or more No Condition is normal. (Noise occurs for 2-3 S immediately
after AlC compressor comes on? after AlC compressor turns on.)
6 INSPECT IDLE SPEED Yes Go to the next step.
• Inspect idle speed. No Follow the repair instruction described in section F, then go
(See 01-10A-20 ENGINE TUNE-UP [WL-3].) to Step 19.
(See 01-108-21 ENGINE TUNE-UP [WL-C,
WE-C).)
• Is it normal?
07-03-8e

7 INSPECT REFRIGERANT AMOUNT Yes Go to Step 10.
• Inspect refrigerant amount. No Go to the next step.
/" ..
• Is it normal?
8 INSPECT REFRIGERANT LINES Yes Go to the next step.
• Inspect refrigerant lines. No If piping or AlC component (s) is damaged or cracked,
- Is piping free of damage and cracks? replace then go to Step 19.
- Are piping connections free of oil grime? If there is gas leakage, repair or replace connection and
(Visual inspection) replace condenser*, then go to Step 19.
- Are piping connections free of gas
leakage?
- Are piping installation points on
condenser free of gas leakage?
- Are piping installation points on receiver/
drier free of gas leakage?
- Are piping installation points on AlC
compressor free of gas leakage?
- Are piping installation points on cooling
unit free of gas leakage
- Perform gas leak inspection using gas
leak tester.
9 INSPECT EVAPORATOR PIPING Yes Adjust refrigerant amount to specified level, then go to Step
CONNECTIONS IN COOLING UNIT FOR GAS 19.
LEAKAGE No If piping is damaged or cracked, replace then go to Step 19.
• Are piping connections for evaporator in If there is gas leakage, repair or replace connection and
cooling unit free of gas leakage? replace condenser*, then go to Step 19.
IS IN COMPRESSOR OIL OR ELSEWHERE No Troubleshooting completed.
• Add 20 ml {20 cc, 0.8 fl oz} of compressor Explain repair to customer.
oil.
• Is noise heard when racing engine?
IS IN AlC COMPRESSOR OR ELSEWHERE No Replace AlC compressor, then go to Step 19.
• Drain compressor oil.
• Is it contaminated with metal particles?
12 CHECK TO SEE WHETHER MALFUNCTION Yes Replace entire AlC system (excluding heater), then go to
IS SOMEWHERE IN AlC SYSTEM OR Step 19.
ELSEWHERE No Go to the next step.
• Is compressor oil whitish and mixed with
water?
13 INSPECT AlC COMPRESSOR OIL Yes Replace AlC compressor and condenser, then go to Step
• Is compressor oil darker than normal and 19. (Since AlC compressor may be worn and receiver/drier
contaminated with aluminum chips? may be clogged, replacement of receiver/drier is
necessary.)
No Condition is normal. Recheck malfunction symptoms.
14 CHECK TO SEE WHETHER MALFUNCTION Yes Replace AlC compressor, then go to Step 19. (AiC
IS IN AlC COMPRESSOR OR ELSEWHERE compressor discharge valve left open)
• Is noise heard immediately after AlC No Go to the next step.
compressor is stopped?
15 INSPECT DRIVE BELT Yes Go to the next step.
• Inspect drive belt. No Adjust or replace drive belt, then go to Step 19.
(See OHOA-3 DRIVE BELT INSPECTION
[WL-3].) (See 01-10B-3 DRIVE BELT
• Is it normal?
16 INSPECT DRIVE BELT CONDITION Yes Remove obstruction, remove oil, or replace drive belt, then
• Is drive belt worn? go to Step 19.
• Does it have foreign material imbedded in it, No Go to the next step.
or have oil on it?
17 INSPECT MAGNETIC CLUTCH Yes Replace AlC compressor (excluding pressure plate, AlC
• Inspect magnetic clutch. compressor pulley, and stator), then go to Step 19.
(See 07-40-5 MAGNETIC CLUTCH No Replace magnetic clutch, then go to Step 19.
INSPECTION.)
• Is it normal?
07-03-9

J.18 CHECK TO SEE WHETHER MALFUNCTION Yes Visually inspect Ale compressor, replace appropriate parts
IS IN AlC COMPRESSOR OR REFRIGERANT if necessary, then go to the next step.
LINES No If noise is due to refrigerant lines, repair detached or
"
• Is noise emitted from Ale compressor? missing clips, tighten loose bolts, then go to the next step.
• Has Ale compressor noise stopped? No Recheck malfunction symptoms, then repeat from Step 1 if
malfunction recurs.
* : If there is gas leakage, air enters into the Ale system. The desiccant within the receiver/drier absorbs the
moisture from the air and becomes saturated. If the Ale system is used in this condition, the inside of the Ale
compressor will begin to rust due to this moisture, which may cause lock up or noise to occur. Therefore,
replacement of the receiver/drier is necessary.
07-03-10
REFRIGERANT SYSTEM
07-10 REFRIGERANT SYSTEM

REFRIGERANT SYSTEM SERVICE REFRIGERANT SYSTEM
WARNINGS ...................... 07-10-1 PERFORMANCE TEST ............. 07-10-2
REFRIGERANT SYSTEM SERVICE REFRIGERANT PRESSURE
CAUTIONS ...................... 07-10-1 CHECK .......................... 07-10-3
REFRIGERANT SYSTEM GENERAL RECOVERy ....................... 07-10-3
PROCEDURES ................... 07-10-2 REFRIGERANT CHARGING .......... 07-10-3
REFRIGERANT SYSTEM SERVICE WARNINGS

dcf071000000w01
Handling Refrigerant
• Avoid breathing air conditioning refrigerant or lubricant vapor. Exposure may irritate eyes, nose and
throat. Also, due to environmental concerns, the use of recovery/recycling/recharging equipment is
mandatory when draining R-134a from the air conditioning system. If accidental system discharge
occurs, ventilate work area before resuming service.
• Do not perform pressure test or leak test for R-134a service equipment and/or vehicle air conditioning
system using compressed air. Some mixtures of air and R-134a have been shown to be combustible at
elevated pressures. These mixtures, if ignited, may cause injury or property damage. Additional health
and safety information may be obtained from refrigerant manufacturers.
• Do not allow the refrigerant to leak near fire or any kind of heat. A poisonous gas may be generated if
the refrigerant gas contacts fire or heat such as from cigarettes and heaters. When carrying out any
operation that can cause refrigerant leakage, extinguish or remove the above-mentioned heat sources
and maintain adequate ventilation.
• Handling liquid refrigerant is dangerous. A drop of it on the skin can result in localized frostbite. When
handling the refrigerant, wear gloves and safety goggles. If refrigerant splashes into the eyes,
immediately wash them with clean water and consult a doctor.
Storing Refrigerant
• The refrigerant container is highly pressurized. If it is subjected to high heat, it could explode,
scattering metal fragments and liquid refrigerant that can seriously injure you. Store the refrigerant at
temperatures below 40°C {104 OF}.
REFRIGERANT SYSTEM SERVICE CAUTIONS

dcf071000000w02
Handling Insufficient Refrigerant Level

• If an insufficient refrigerant level is detected at troubleshooting, do not charge (add) the refrigerant.
Because an accurate amount of refrigerant cannot be determined from the pressure indicated on the
manifold gauge, never charge the refrigerant. If there is too much or too little refrigerant from the
refilling, there may be secondary problems such as damage to the refrigerant cycle parts, or a decrease
of cooling performance. Therefore, if it is determined that the refrigerant level is insufficient,
completely remove refrigerant from the refrigerant cycle and refill with refrigerant to the specified
amount.
Handling AlC Related Parts

• There will be no effect on either performance or quality of AlC-related parts, including but not limited to
the piping, etc., provided that said parts are serviced/repaired in accordance with standard procedure.
• When serviced/repaired AlC units in locations where there is a considerable risk of contamination from
dirt or dust, plug up the openings on the parts to prevent dust/dirt from entering.
• When using adhesive material to cover openings on AlC parts, make sure that the adhesive side of the
material does not come in contact with the connectors on the parts.
• When the system is opened to atmosphere, there is no need to replace the condenser, or the receiver
dryer when it is housed within the condenser, provided that the unit is plugged accordingly.
07-10-1
REFRIGERANT SYSTEM
Handling Compressor Oil
• Use only FD46XG compressor oil for this FD46XG COMPRESSOR OIL
vehicle. Using a PAG oil other than FD46XG z
compressor oil can damage the AlC o
compressor. ti:
a:
I
I
• Do not spill FD46XG compressor oil on the o

I
I
I
vehicle. A drop of compressor oil on the C/)
co I
vehicle surface can eat away at the paint. If oil « I

I
w I
gets on the vehicle, wipe it off immediately. a: I

:::> I
I
• FD46XG compressor oil (PAG oil) has a higher
moisture absorption efficiency than the
tn :MINERAL OIL
5
previously used mineral oil. If moisture mixes :2 0 ~~~~===~~==;::= • TIME
with the compressor oil, the refrigerant
DBG710ZWB001
system could be damaged. Therefore, install
caps immediately after using the compressor
oil or removing refrigerant system parts to prevent moisture absorption.
REFRIGERANT SYSTEM GENERAL PROCEDURES

dcf071000000w03
1. Fully close the valves of the SST (49 C061 001 A).
2. Connect the SSTs (49 C061 002,49 C061 003)
to the high- and low-pressure side joints of the 'J' I. II •
SST (49 C061 001A).
.. em,;",..
3. Connect the SSTs (49 C061 006A, 49 C061 007) ~. I • I I
to the ends of the SSTs (49 C061 002,49 C061
l~:!'~ ~
I. II. '
003).
:A'
4. Connect the SSTs (49 C061 006A, 49 C061 007) CAP
~HARGING
to the charging valves.
CAP~
~_~ALVEOF
CHARGING VALVE OF ~ HIGH-PRESSURE
LOW-PRESSURE SIDE ---- SIDE
BHE0710W001
-
"
REFRIGERANT SYSTEM PERFORMANCE TEST

dcf071000000w04
1. Inspect the refrigerant pressure. (See 07-10-3 REFRIGERANT PRESSURE CHECK.)

2. Place a dry-bulb thermometer in the driver-side center ventilator outlet.
3. Start the engine and after it is warmed up, run it at a constant 1,500 rpm.
4. Set the fan speed to MAX HI.
5. Turn the AlC switch on.
6. Set to RECIRCULATE mode.
7. Set the temperature control to MAX COLD.
8. Set to VENT mode.
9. Close all the doors and windows.
10. Wait until the air conditioner output temperature stabilizes.
Stabilized condition
• The AIC compressor repeatedly turns on and off at regular intervals.
11. After the blower air is stabilized, read the dry-bulb thermometer.
12. Verify the ambient temperature.
13. Verify that the temperature reading is in the
a: °C {OF}
shaded zone. o
• If the there is any malfunction, inspect the 6 {43}r
~
-w
refrigerant system according to the f-a: 5 4 {41}f-
{39} f- ~
troubleshooting chart. m:::> 3 {37} f-
>!;:(
a: a: 2 {36}r
ww 1 {34} f-
f-a.
Z:2
Ww
o {32} L...-~-II():)'----!-:X-~'-..o.....o...,.l:C....J:o:...x-:.:><::..~c.J
Of- .. 20 25 30 35 40°C
{68} {77} {85} {95} {104} {OF}
AMBIENTTEMPF.RATURE
DBG710ZWB003
07-10-2
REFRIGERANT SYSTEM
REFRIGERANT PRESSURE CHECK
dcf071078834w01
1. Install the SSTs (49 C061 OAOS).

2. Start the engine and after it is warmed up, run it at a constant 1,500 rpm.
3. Set the fan speed MAX HI.
5. Set to RECIRCULATE mode.
6. Set the temperature control to MAX COLD.
7. Set to VENT mode.
8. Close all the doors and all the windows.
9. Measure the ambient temperature and high- and low- pressure side reading of the SST (49 C061 001 A).
10. Verify that the intersection of the pressure reading
of the SST (49 C061 001 A) and ambient MPa
temperature is in the shaded zone. {kgf/cm 2 , psi}
HIGH-PRESSURE SIDE
• If there is any malfunction, inspect the ~ 2.0
refrigerant system according to the ~ {21, 299}
troubleshooting chart. C9
Cl 1.5
B {15,213}
LL
Z 1.0
« {10, 142}
:2
LL
oC9 0.2 LOW-PRESSURE SIDE
z {2.0,28}
is
«
w
II: 0.1
~ {1.0,14}
::l
(f)
(f)
w
~ 1____~__~~__
- I
20
I
25
I
L __ _
30
~ ~
I __ I
35 40°C
{68} {77} {85} {95} {104} {OF}
AMBIENT TEMPERATURE
DBG710ZWB002
RECOVERY
dcf071078834w02
1. Connect an R-134a recovery/recycling/recharging device to the vehicle and follow the device manufacturer's
instructions.
REFRIGERANT CHARGING
dcf071078834w03
Caution
• Do not exceed the specification when charging the system with refrigerant. Doing so will decrease
the efficiency of the air conditioner or damage the refrigeration cycle parts.
Charging Recycled R-134a Refrigerant

1. Connect an R-134a recovery/recycling/recharging device to the vehicle and follow the device manufacturer's
instructions.
07-10-3
REFRIGERANT SYSTEM
Charging Preparation
1. Install the SSTs (49 C061 OAOS).
2. Connect the tap pin side of the SST (49 C061 004) to the air purge valve of the SST (49C061 001).
3. Connect the SST (49 C061 005) to the center joint of the SST (49 C061 001A).
4. Connect the SST (49 C061 005) to the vacuum pump.
5. Connect the SST (49 C061 004) to the refrigerant tank.
6. Place the refrigerant tank on the scale. r---TA-P-P-I-N-S-IDn-E-7-~A-;-;:_IR.:-;:P::7"~.;-;::;R""G-;:::-;-;-=-;-;-;-;:::---,-,-.-,- ••- , - - '
Regular amount of refrigerant (approx.

quantity)
475 g {16.8 oz} Ck'INa"!.u· " ., ••
REFRIGER:gNT ~f~~~~=~
@}- : ---::
TANK .
SCALE
@8
r:=:.=e:" VACUUM PUMP
BHE0710W004
Evacuation
1. Open all the valves of the SST (49 C061 001 A).
Caution
• Close the SST (49 C061 001 A) valve immediately after stopping the vacuum pump. If the valve is
left open, the vacuum pump oil will flow back into the refrigeration cycle and cause a decrease in
the efficiency of the air conditioner.
2. Start the vacuum pump and let it operate for 15

min. :4' I. II j,
CLOSE
BHE0710W005
3. Verify that high- and low-pressure side readings

of the SST (49 C061 001A) are at -101 kPa {-
760 mmHg, -29.9 inHg}. Close each valve of the
SST (49 C061 001A).
BHE0710W002
Airtightness Check
1. Stop the vacuum pump and wait for 5 min.
2. Check the high- and low-pressure side readings of the SST (49 C061 001A) .
• If the reading has changed, inspect for leakage and go to Evacuation. (See 07-10-4 Evacuation.)
• If the reading has not changed, go to Charging New R-134a Refrigerant. (See 07-10-5 Charging New R-
134a Refrigerant.)
07-10-4
REFRIGERANT SYSTEM
Charging New R-134a Refrigerant
1. Open the valve of the refrigerant tank.
2. Weigh the refrigerant tank to charge the suitable amount of refrigerant.
Warning
• If the refrigerant system is charged with a large amount of refrigerant when inspecting for gas
leakage, and if any leakage should occur, the refrigerant will be released into the atmosphere. In
order to prevent the accidental release of refrigerant which can destroy the ozone layer in the
stratosphere, follow the proper procedures and charge with only a small amount of refrigerant
when inspecting for gas leakage.
• If charging the system with refrigerant using service cans, running the engine with the 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.
Caution
• Always being charging of refrigerant from the high-pressure side. If changing is begun from the
low-pressure side, the vanes of the AlC compressor will not be released and abnormal noise may
result.
3. Open the low-pressure side valve of the SST (49

C061 001A).
4. When the high-pressure side reading increases to

0.098 MPa {1.0 kgf/cm 2 , 14 psi}, close the ,. I. II •
low-pressure side valve of the SST (49 C061
001A).
5. Inspect for leakage from the cooler pipe/hose
connections using the SST (49 C061 013).
• If there is no leakage, go to Step 7.
• If leakage is found at a loose joint, tighten the
joint, then go to next step.
6. Inspect for leakage again.
• If there is no leakage after tightening the joint,
go to next step.
• If there is still a leakage at the same joint,
discharge the refrigerant and then repair the
joint. Repeat the charging procedure from evacuation.
Warning
• If charging the system with refrigerant using service cans, running the engine with the
high-pressure side valve open is dangerous. Pressure within the service cans will increase and
the cans could explode, scattering metal fragments and liquid refrigerant that can seriously injure
you. Therefore, do not open the high-pressure side valve while the engine is running.
07-10-5
REFRIGERANT SYSTEM
C061 001 A) and charge with refrigerant until the
weight of refrigerant tank has decreased 250 g
{8.83 oz} from the amount in Step 2.
OPEN
8. Close the low-pressure side valve of the SST (49

C061 001A).
Warning
• If charging the system with refrigerant
using service cans, running the engine
with the high-pressure side valve open is
dangerous. Pressure within the service
cans will increase and the cans could
explode, scattering metal fragments and
liquid refrigerant that can seriously injure
you. Therefore, do not open the
BHE0710W002
high-pressure side valve while the engine
is running.
9. Start the engine and actuate the A/C compressor.

C061 001 A) and charge with refrigerant until the
weight of the refrigerant tank has decreased
regular amount from the amount in Step 2.
11. Close the low-pressure side valve of the SST (49 OPEN
C061 001 A) and the valve of the refrigerant tank.
12. Stop the engine and A/C compressor.
BHE0710W007
Leak Test
1. Inspect for leakage using the SST (49 C061 013).
• If there is no leakage, go to Step 3.
• If leakage is found at a loose joint, tighten the joint, then go to next step.
2. Inspect for leakage again.
• If there is no leakage after tightening the joint, go to next step.
• If there is still leakage at the same joint, discharge the refrigerant and then repair the joint. Repeat the
charging procedure from evacuation.
3. Disconhect the SSTs (49 C061 006A, 49 C061 007) from the charging valves.
4. Install the caps to the charging valves. ,-----~--;-;---------------,
CHU0710W006
07-10-6
BASIC SYSTEM
07-11 BASIC SYSTEM

HVAC BASIC SYSTEM AIR OUTLET DUCT
LOCATION INDEX . ................ 07-11-1 REMOVAUINSTALLATION ......... . 07-11-5
BLOWER UNIT AIR OUTLET DUCT
REMOVAUINSTALLATION .......... 07-11-2 DISASSEMBLY/ASSEMBLY . ....... . 07-11-6
BLOWER UNIT AlC COMPRESSOR
DISASSEMBLY/ASSEMBLY . ........ 07-11-2 REMOVAUINSTALLATION ......... . 07-11-6
COOLING UNIT CONDENSER
REMOVAUINSTALLATION .......... 07-11-3 REMOVAUINSTALLATION ......... . 07-11-8
COOLING UNIT CONDENSER INSPECTION ......... . 07-11-8
DISASSEMBLY/ASSEMBLY . ........ 07-11-4 REFRIGERANT LINES
EVAPORATOR INSPECTION . ........ 07-11-5 REMOVAUINSTALLATION ......... . 07-11-8
HVAC BASIC SYSTEM LOCATION INDEX
arnffw00000449
1 Heater unit 5 AlC compressor

2 Cooling unit (See 07-11-6 AlC COMPRESSOR REMOVAU
(See 07-11-2 COOLING UNIT REMOVAU INSTALLATION. )
INSTALLATION.) 6 Refrigerant line
(See 07-11-4 COOLING UNIT DISASSEMBLY/ (See 07-11-8 REFRIGERANT LINES REMOVAU
ASSEMBLY.) INSTALLATION.)
3 Blower unit 7 Heater hose
(See 07-11-5 BLOWER UNIT DISASSEMBLY/
ASSEMBLY.)
4 Condenser
07-11-1
BASIC SYSTEM
BLOWER UNIT REMOVAL/INSTALLATION
dcf07116114OW01
2. Remove the glove compartment. (See 09-17-9 GLOVE COMPARTMENT REMOVAL/INSTALLATION.)
3. Remove the cooling unit. (See 07-11 ~3 COOLING UNIT REMOVAL/INSTALLATION.)
1 Connector
2 Nut
3 Blower unit
DBG711 ZWB002
BLOWER UNIT DISASSEMBLY/ASSEMBLY

dcfD7116114OW02
Caution
• Apply only the specified grease to the link. Otherwise abnormal noise or improper operation may
result.
1 Blower motor
2 Resistor
3 Blower wiring harness
4 Air intake link
5 Air intake crank
6 Polyurethane protector
7 Blower case (1)
8 Blower case (2)
9 Air interke door
10 Blower case (3)
11 Blower case (4)
07-11-2
BASIC SYSTEM
COOLING UNIT REMOVAUINSTALLATION
dcf071161520w01

2. Discharge the refrigerant from the system. (See 07-10-3 REFRIGERANT CHARGING.)
3. Remove the glove compartment. (See 09-17-9 GLOVE COMPARTMENT REMOVAUINSTALLATION.)
4. Disconnect the air intake wire from the blower unit. (See 07-40-8 CLIMATE CONTROL UNIT WIRE
ADJUSTMENT.)
Caution
• If moisture or foreign material enters the refrigeration cycle, cooling ability will be lowered and
abnormal noise will occur. Always immediately plug all open fittings after removing any
refrigeration cycle parts to keep moisture or foreign material out of the cycle.
5. Remove in the order indicated in the table. Do not

allow compressor oil to spill.
1 Cooler hose (LO)

(See 07-11-9 Refrigerant Line Removal Note.)
(See 07-11-9 Refrigerant Line Installation Note.)
2 Cooler pipe
3 Cooling unit
(See 07-11-3 Cooling Unit Installation Note.)
6. Install in the reverse order of removal. 9.81~19.61 N·m

{100-200 kgf·cm,
7. Perform the refrigerant system performance test. 86.8-173.5 in·lbf}
PERFORMANCE TEST.)
DBG711ZWB018
DBG711 ZWB025
Cooling Unit Installation Note

1. When installing a new cooling unit (evaporator), add FD46XG compressor oil into the refrigerant cycle.
Supplemental amount (approx. quantity)

40 ml {40 cc, 1.4 fl oz}
07-11-3
BASIC SYSTEM
COOLING UNIT DISASSEMBLY/ASSEMBLY
dcf07116152Ow02
Caution

1 Polyurethane protector
2 Cooler case (1)
3 Cooler case (2)
4 Thermistor
(See 07-11-5 Thermistor Assembly Note.)
5 Evaporator
6 Expansion valve
(See 07-11-4 Expansion Valve assembly Note.)
7 High pressure pipe
DBG711 ZWB020
Expansion Valve assembly Note

• Replace the O-rings at the expansion valve joints and apply compressor oil to the O-rings and connect the
joints.
• Tighten the joint to the specified torque using two open-end wrenches.
• Assemble the heat-sensing tube as shown in the r--=-2::-0-~2::-:4-:-N:-.m-------------------'
figure. {2.0-2.5 kgf·m,
15-18 ft·lbf}
11.8-14.7 N·m
HEAT-SENSING TUBE
DBG711 ZWB009
07-11-4
BASIC SYSTEM
Thermistor Assembly Note
1. Assemble the thermistor as shown in the figure. I
EVAPORATOR
., Ir
40mm
1{1.6 in}
4 LINE
arnffw00000020
EVAPORATOR INSPECTION
dcf07116181Ow01
1. Remove the cooling unit. (See 07-11-3 COOLING UNIT REMOVAL/INSTALLATION.)

2. Remove the evaporator from the cooling unit.
3. Check for cracks, damage, and oil leakage. If an problems found, replace the evaporator.
4. Check for bent fins. in they are bent, use a flat-head screwdriver to straighten them.
AIR OUTLET DUCT REMOVAUINSTALLATION

dcf07116012Ow01

2. Remove the dashboard. (See 09-17-4 DASHBOARD REMOVAL/INSTALLATION.)
3. Remove as indicated in the table. ,----------------------,
I ~ I~i~toutlet duct
DBG711ZWB012
07-11-5
BASIC SYSTEM
AIR OUTLET DUCT DISASSEMBLY/ASSEMBLY
dcf07116012Ow02
DBG740ZWB033
1 Airflow mode main link 5 Case (2)

2 Airflow mode link 6 Case (3)
3 Airflow mode link set 7 Airflow mode door
4 Case (1)
AlC COMPRESSOR REMOVAL/INSTALLATION

dcf07116145Ow01

3. Remove the drive belt.
4. Loosen the AIC compressor bolts, then slide the AIC compressor.
Caution
07-11-6
BASIC SYSTEM
5. Remove in the order indicated in the table. Do not
allow compressor oil to spill.
1 Cooler hose (HI)
2 Cooler hose (LO)
3 Magnetic connector
4 AlC compressor
(See 07-11-7 AlC Compressor Installation Note.)

7. Adjust the drive belt. (See 01-10A-4 DRIVE BELT
ADJUSTMENT [WL-3].) (See 01-10B-4 DRIVE
BELT ADJUSTMENT [WL-C, WE-C].)
8. Perform the refrigerant system performance test.
PERFORMANCE TEST.)
A: 15-21 N·m {1.6-2.1 kgf·m, 12-15 ft·lbf}

B: 24-35 N·m {2.4-3.6 kgf.m, 18-26 ft·lbf}
c: 17.6-26.5 N;m {1.80-2.70 kgf·m, 13.0-19.5 ft·lbf}
DBG711 ZWB024
AlC Compressor Installation Note
Caution
• Due to the high moisture-absorption characteristics of the compressor oil, it may absorb moisture
if left over a long period of time thereby negatively affecting AlC operation. Drain the compressor
oil and refill within 10 min. of each other.
1. Rotate new AlC compressor shaft six to eight revolutions while collecting refrigerant oil in a clean measuring
device. Use this refrigerant oil to refill new compressor. Do not allow refrigerant oil to become contaminated.
2. Rotate old A/C compressor shaft six to eight revolutions while collecting refrigerant oil in a separate, clean
measuring device.
3. Compare those oil amounts. The amount of the oil drained from the new AlC compressor should be greater
than the old one.
4. Pour the same amount oil of drained from the old
NEW AlC COMPRESSOR OLD AlC COMPRESSOR
AlC compressor back into the new AlC
compressor.
AlC compressor oil type

• FD46XG
AlC compressor oil sealed volume (approx.

quantity)
• 180 ml {180 cc, 6.08 fl oz}
SAME
AMOUNT
DBG711ZWB016
07-11-7
BASIC SYSTEM
CONDENSER REMOVAL/INSTALLATION
dcf07116148Ow01

3. Remove the radiator grill. (See 09-16-3 RADIATOR GRILLE REMOVAUINSTALLATION.)
4. Remove the charge air cooler. (See 01-13A-2 INTAKE-AIR SYSTEM REMOVAUINSTALLATION [WL-3].) (See
01-13B-3INTAKE-AIR SYSTEM REMOVAUINSTALLATION [WL-C, WE-C].)
5. Disconnect the cooler hose (HI) and cooler pipe. Do not allow remaining compressor oil in the refrigerant line to
spill.
Caution
abnormal noise or other malfunction could occur. Always plug open fittings immediately after
removing any refrigeration cycle parts.
1 Nut
2 Condenser
(See 07-11-8 Condenser Installation Note.)

PERFORMANCE TEST.)
DBG711 ZWB029
Condenser Installation Note

1. After replacing the condenser, add compressor oil to the refrigeration cycle.
Supplemental oil amount (approx. quantity)

20 ml {20 cc, 0.7 fl oz}
CONDENSER INSPECTION
dcf07116148Ow02
1. Inspect the condenser for cracks, damage, and oil. leakage.
• If there is any malfunction, replace the condenser.
2. Visually inspect the fins for clogging of foreign material.
• If any fins are clogged, remove the foreign material.
3. Visually inspect the fins for bending.
• If there is any bending, use the end of a flathead screwdriver to straighten fins.
REFRIGERANT LINES REMOVAL/INSTALLATION

dcf07116146Ow01
2. Discharge the refrigerant from the system. (See 07-10-3 RECOVERY.) (See 07-10-3 REFRIGERANT
CHARGING.)
Caution
3. Remove the radiator grille. (See 09-16-3 RADIATOR GRILLE REMOVAUINSTALLATION.)
07-11-8
BASIC SYSTEM
4. Remove in the order indicated in the table. Do not allow compressor oil to spill.
A: 6.85-9.80 N·m {70-100 kgf·cm, 60.8-86.7 in.lbf}

B: 15-21 N'm {1.5-2.2 kgf·m, 11-15 ft·lbf}
C: 20-29 N'm {2.0-3.0 kgf·m, 15-21 ft·lbf}
D: 9.81-19.61 N·m {100-200 kgf·cm, 86.8-173.5 in·lbf}
E: 24-35 N'm {2.4-3.6 kgf·m, 18-26 ft·lbf}
DBG711 ZWB028
Cooler hose (LO) 2 Cooler hose (HI)

(See 07-11-9 Cooler Hose Removal Note.) (See 07-11-9 Cooler Hose Removal Note.)
(See 07-11-9 Refrigerant Line Removal Note.) (See 07-11-9 Refrigerant Line Removal Note.)
(See 07-11-9 Refrigerant Line Installation Note.) (See 07-11-9 Refrigerant Line Installation Note.)
3 Cooler pipe

6. Perform the refrigerant system performance test. (See 07-10-2 REFRIGERANT SYSTEM PERFORMANCE
TEST.)
Cooler Hose Removal Note
WL-3 only
• Loosen the A/C compressor bolts, then slide the A/C compressor, and remove the cooler hose bolt from the AI
C compressor.
Refrigerant Line Removal Note
• Loosen the nut by using two spanners, then remove the cooler pipe or hose.
Refrigerant Line Installation Note
1. When installing a new cooler pipe or hose, add FD46XG compressor oil into the refrigeration cycle.
Supplemental amount
• Cooler hose (LO): 8 ml {8 ee, 0.3 fl oz}
• Cooler hose (HI): 5 ml {5 ee, 0.2 fl oz}
• Cooler pipe: 3 ml {3 ee, Q.1 fl oz}
2. Apply compressor oil to the O-rings and connect the joints.
3. Tighten the joints.
(1) Tighten the nut or bolt of the joint by hand.
(2) Tighten the joint to the specified torque. If it is a nut joint, tighten the nut using a spanner and torque
wrench.
07-11-9
CONTROL SYSTEM
07-40 CONTROL SYSTEM

HVAC CONTROL SYSTEM LOCATION REFRIGERANT PRESSURE SWITCH
INDEX .......................... 07-40-1 REMOVAUINSTALLATION .......... 07-40-6
BLOWER MOTOR REFRIGERANT PRESSURE SWITCH
REMOVAUINSTALLATION .......... 07-40-2 INSPECTION ..................... 07-40-6
BLOWER MOTOR INSPECTION ...... 07-40-2 CLIMATE CONTROL UNIT
RESISTOR REMOVAL. ....................... 07-40-7
REMOVAUINSTALLATION .......... 07-40-3 CLIMATE CONTROL UNIT
RESISTOR INSPECTION ............ 07-40-3 INSTALLATION .................... 07-40-7
MAGNETIC CLUTCH CLIMATE CONTROL UNIT
DISASSEMBLY/ASSEMBLY ......... 07-40-3 DISASSEMBLY/ASSEMBLY ......... 07-40-8
MAGNETIC CLUTCH ADJUSTMENT ... 07-40-4 CLIMATE CONTROL UNIT WIRE
MAGNETIC CLUTCH INSPECTION .... 07-40-5 ADJUSTMENT .................... 07-40-8
THERMISTOR AlC AMPLIFIER INSPECTION ......... 07-40-9
REMOVAUINSTALLATION .......... 07-40-5 AlCSWITCH
THERMISTOR INSPECTION ......... 07-40-5 REMOVAUINSTALLATION .......... 07-40-10
AlC SWITCH INSPECTION ........... 07-40-10
FAN SWITCH INSPECTION ........... 07-40-10
HVAC CONTROL SYSTEM LOCATION INDEX

dcfO?400000OW01
DBG740ZWB001
1 Blower motor 4 Magnetic clutch

(See 07-40-2 BLOWER MOTOR REMOVAU (See 07-40-3 MAGNETIC CLUTCH
INSTALLATION.) DISASSEMBLY/ASSEMBLY.)
(See 07-40-2 BLOWER MOTOR INSPECTION.) (See 07-40-4 MAGNETIC CLUTCH
2 Resistor ADJUSTMENT.)
(See 07-40-3 RESISTOR REMOVAU (See 07-40-5 MAGNETIC CLUTCH INSPECTION.)
INSTALLATION.) 5 Refrigerant pressure switch
(See 07-40-3 RESISTOR INSPECTION.) (See 07-40-6 REFRIGERANT PRESSURE
( 3 Thermistor SWITCH REMOVAUINSTALLATION.)
(See 07-40-5 THERMISTOR REMOVAU (See 07-40-6 REFRIGERANT PRESSURE
INSTALLATION.) SWITCH INSPECTION.)
(See 07-40-5 THERMISTOR INSPECTION.)
07-40-1
CONTROL SYSTEM
6 Climate control unit 7 lAIC relay

(See 07-40-7 CLIMATE CONTROL UNIT
REMOVAL.)
INSTALLATION.)
(See 07-40-8 CLIMATE CONTROL UNIT WIRE
ADJUSTMENT.)
BLOWER MOTOR REMOVAL/INSTALLATION

dcf074061020w01
1. Disconnect negative battery cable.
1 Blower motor connector
2 Screw
3 Blower motor
l
DBG740ZWB016
BLOWER MOTOR INSPECTION

dcf074061020w02
Connect battery positive voltage to blower motor terminal A, connect terminal B to ground, and then verify its
operation.
• If there is any malfunction, replace the blower
motor.
ADJ8540W108
07-40-2
CONTROL SYSTEM
RESISTOR REMOVAUINSTALLATION
dcf074061015w01

1 Resistor connector
2 Screw
3 Resistor
l
DBG740ZWB018
RESISTOR INSPECTION
dcf074061015w02
1. Verify that the resistance between the resistor

terminals is as shown in the table.
• If th ere IS any ma If unctl~n, repie
I t he
resistor. R3 R2 R1
Terminal Resistance (ohm)
1A-1B (2A) R1: 0.43-0.47
1A-1C R2: 1.04-1.16
1C-1D R3: 1.47-1.63
DBG740ZWB019
MAGNETIC CLUTCH DISASSEMBLY/ASSEMBLY

dcf074061010w01

1 Bolt
(See 07-40-4 Bolt Removal/Installation Note.)
2 Pressure plate
(See 07-40-4 Pressure Plate Installation Note.)
3 Shim
4 Snap ring
5 AlC compressor pulley
6 Screw
7 Stator
(See 07-40-4 Stator Removal Note.)
(See 07-40-4 Stator Installation Note.)
8 Snap ring
9 AlC compressor body

3. Adjust the magnetic clutch clearance. (See 07-40-
4 MAGNETIC CLUTCH ADJUSTMENT.)
07-40-3
CONTROL SYSTEM
Bolt Removal/Installation Note
1. When removing or installing the bolt, hold the
pressure plate in place as shown in the figure.
2. When installing a new Ale compressor body,
replace the recommended bolt.
DBG740ZWB006
Stator Removal Note

1. Set a straight-socket (17 mm {0.67 in}) on the shaft of the Ale compressor to protect it.
2. Remove the stator using a pulley puller as shown
in the figure. STRAIGHT-SOKET
(17mm {O.67 in})
DBG740ZWB028
Stator Installation Note

1. Install the stator perpendicularly using the SST
(49 H061 005) and a pulley puller as shown in the
figure.
PULLEY PULLER •
tpl:ltI$I.r,~
•• o~
DBG740ZWB029
Pressure Plate Installation Note

1. When installing the pressure plate, carry out magnetic clutch clearance adjustment.
MAGNETIC CLUTCH ADJUSTMENT
1. Set the Ale compressor on a level block.

2. Turn on the magnetic clutch by connecting the battery MEASURING
PROBE
voltage to the magnetic clutch connector terminal and
the ground to the Ale compressor body.
3. Fix a dial gauge on a magnetic base and set the
measuring probe onto point A on the pressure
plate surface. MAGNETIC
BASE
4. Turn off the magnetic clutch by disconnecting the
ground from the Ale compressor body, then LEVEL BLOCK
measure the dial gauge readings.
T===========~'/ . arnffw00000025
07-40-4
CONTROL SYSTEM
5. Measure the clearance for point Band C on the MEASURING POINT

pressure plate surface by repeating the above
steps 2 through 4.
A B
Clearance
0.35-0.75 mm {0.014-0.029 in}
arnffwOOOOO026
6. If the clearance is not as specified, adjust it by

changing the shim. :>-SHIM
Note
~~II~~~Ii~I!~NCCOMPRESSOR
• 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.
arnffw00000027
07-40-4a
CONTROL SYSTEM
MAGNETIC CLUTCH INSPECTION

dcfO?406101Ow03
1. Connect battery positive voltage to terminal A of
magnetic clutch and the ground to AlC
compressor body.
2. Verify that the magnetic clutch operates .
• If there is any malfunction, replace the stator.
DBG?40ZWB007
THERMISTOR REMOVAUINSTALLATION
dcfO?4061 022w01
1. Remove the thermistor from the cooling unit. (See 07-11-4 COOLING UNIT DISASSEMBLY/ASSEMBLY.)
THERMISTOR INSPECTION
dcfO? 4061 022w02
2. Remove the cooling unit. (See 07-11-3 COOLING UNIT REMOVAUINSTALLATION.)
3. Remove the thermistor. (See 07-11-4 COOLING UNIT DISASSEMBLY/ASSEMBLY.)
5. Connect the thermistor connector to the wiring harness connector.
6. Turn the ignition switch to on position.
8. Turn the fan switch on.
9. Immerse the sensor part of thermistor in a container of ice water.
10. Verify that magnetic clutch operate as shown below.
• If not as specified, replace the thermistor.
Magnetic
Water temperature Differential
clutch
0-3°C 3-5°C
{38-41 OF} OFF
{32-37°F}
13-17°C 2-6°C
OFF
{34-62°F} {36-42°F}
07-40-5
CONTROL SYSTEM
REFRIGERANT PRESSURE SWITCH REMOVAUINSTALLATION
dcf074061503w01

~. Discharge the refrigerant from the system. (See 07-10-3 RECOVERY.) (See 07-10-3 REFRIGERANT
CHARGING.)
Caution

Refrigerant pressure switch connector
Refrigerant pressure switch

PERFORMANCE TEST.)
DBG740ZWB010
Refrigerant Pressure Switch Installation Note

1. Apply compressor oil to O-ring and connect the joint.
REFRIGERANT PRESSURE SWITCH INSPECTION

dcf074061503w02
1. Install the SST (gas charging set).

2. Disconnect the refrigerant pressure switch connector.
3. Verify the high-pressure side reading of the SST
(manifold gauge) and continuity between the
refrigerant pressure switch terminals. 0.176-0.216 2.94-3.34
·-----r - 1
{1.795-2.202, 25.53~31.31} {30.0-34.0, 427-4B3}
refrigerant pressure switch.
ON
OFF nmnn,
i. .L------1 t
I
0.02
I
i
I
• • •
0.39-0.79
I
i
{3.9B-B.05,57-114}
{0.20,2.B4}
or less MPa {kgf/cm2, psi}
DBG740ZWB011
07-40-6
CONTROL SYSTEM
CLIMATE CONTROL UNIT REMOVAL
dcf074061190w01

2. Remove the glove compartment. (See 09-17-9 GLOVE COMPARTMENT REMOVAUINSTALLATION.) t ..
3. Remove the center panel module or audio unit. (See 09-20-3 CENTER PANEL UNIT REMOVAU
INSTALLATION [TYPE A].) (See 09-20-5 AUDIO UNIT REMOVAUINSTALLATION [TYPE 8].)
4. Disconnect the connector A.
5. Disconnect the air intake wire from the blower unit.
6. Disconnect the airflow mode wire from the air outlet duct.
7. Release the left and right tabs and remove in the b;::;~~~=====::::~~/-/~=::::::~~I
order indicated in the table.
IConnector B
-;
DBG740ZWB03lf tff
CLIMATE CONTROL UNIT INSTALLATION

dcf074061190w02
1. Connect the climate control unit connectors.

2. Insert the climate control unit until each clip clicks.
3. Adjust the climate control unit wire. (See 07-40-8
CLIMATE CONTROL UNIT WIRE
ADJUSTMENT.)
4. Install the center panel module or audio unit. (See
09-20-3 CENTER PANEL UNIT REMOVAU
INSTALLATION [TYPE A].) (See 09-20-5 AUDIO
UNIT REMOVAUINSTALLATION [TYPE 8].)
5. Install the glove compartment. (See 09-17-9
GLOVE COMPARTMENT REMOVAU
INSTALLATION.)
DBG740ZWBO
07-40-7
CONTROL SYSTEM
CLIMATE CONTROL UNIT DISASSEMBLY/ASSEMBLY
dcf07406119OW03
1 Panel
2 Airflow mode wire
3 Air intake wire
4 AlC amplifier
5 Fan switch
6 Climate control unit harness
7 Illumination bulb
8 Body
DBG740ZWB037
CLIMATE CONTROL UNIT WIRE ADJUSTMENT

dcf07406119OW04
Air Intake Wire
1. Set the REC/FRESH lever at REC .
. ,2. Set the air intake link to REC in the direction of
. the arrow and insert a screwdriver into the set
,,' hole.
3. Connect the air intake wire to the air intake link.
4. Clamp the air intake wire to wire clamp.
5. Verify that the REC/FRESH lever moves its full
stroke. SET HOLE
DBG740ZWB041
Airflow Mode Wire

1. Set the airflow mode control dial at DEFROSTER.
2. Set the airflow mode link to DEFROSTER in the
direction of the arrow and insert a screwdriver into
the set hole.
3. Connect the airflow mode wire to the airflow mode
link.
4. Clamp the airflow mode wire to wire clamp.
5. Verify that the airflow mode control dial moves its
full stroke.
07-40-8
CONTROL SYSTEM
AlC AMPLIFIER INSPECTION
delO?4061190w05
1.Connect the AlC amplifier connector.

2.Turn the engine switch to the ON position. f
3.Connect the negative (-) lead of the tester to body ground.
4.By inserting the positive (+) lead of the tester into each AlC amplifier terminal, measure the voltage according
to the terminal voltage table .
• If there is any malfunction, inspect the parts under "Inspection item (s)".
- If the parts under "Inspection item (s)", replace the AlC amplifier.
Terminal Voltage Table
DBG740ZWB699
Term Signal Measurement

Connected to Voltage (V) Inspection item (s)
inal name condition
• Inspect for continuity or short circuit (AI
Engine switch at ON C amplifier-AlC2 10 A fuse:1A-AlC2
B+
position 10 A fuse
1A IG2 AlC2 10 A fuse
• Inspect AlC2 10 A fuse
Engine switch at LOCK
Below 1.0 • Inspect short circuit (AIC amplifier-AI
position C210 A fuse: 1A-AlC2 10 A fuse)
• Inspect or continuity or short circuit (AIC
AlC switch OFF B+ amplifier-AIC relay: 1B-Inspect AlC
1B AlC AlC relay relay
AlC switch ON Below 1.0 • Inspect terminal voltage of AlC amplifier

(1A)
GND Ground Under any condition Below 1.0 • Inspect for continuity (AIC amplifier-
1C
ground:1 C-GND) I
Thermistor Side
1. Connect the thermistor connector.
3. Turn the fan switch ON.
4. Turn the AlC switch ON.
5. Connect the positive (+) and negative (-) probes
of the voltmeter to terminal 2A and terminal 2B of
the thermistor respectively. (The wiring harness
connector must be connected to the thermistor
connector.)
6. If there is any malfunction, replace the AlC
amplifier.
DBG740ZWB600
. ,.~
07-40-9
CONTROL SYSTEM
AlC SWITCH REMOVAUINSTALLATION
dcf07406119Ow06

!. Remove the center panel module or audio unit. (See 09-20-3 CENTER PANEL UNIT REMOVAU
INSTALLATION [TYPE A].) (See 09-20-5 AUDIO UNIT REMOVAUINSTALLATION [TYPE 8].)
3. Disconnect the AlC switch connector.
4. Release the left and right tabs and remove the AI
C switch as shown in the figure.
DBG740ZWB045
AlC SWITCH INSPECTION

dcf07406119Ow07
1. Inspect for continuity between the AIC switch

terminals using a tester.
o--®-O : Bulb 0--0: Continuity

Switch Terminal
position A B C D E
OFF 0 D
ON 0 D 0 -0
DBG740ZWB044
DBG740ZWB043
2. Connect battery positive voltage to terminal D and
ground to the terminal C.
4. Verify that the LED illuminates.
• If there is any malfunction, replace the AlC switch.
FAN SWITCH INSPECTION

dclO74061050w01
1. Remove the climate control unit. (See 07-40-7 CLIMATE CONTROL UNIT REMOVAL.) (See 07-40-7 CLIMATE
CONTROL UNIT INSTALLATION.)
2. Verify that the continuity between the fan switch terminals is as indicated in the table.
• If there is any malfunction, replace the fan
switch.
0--0: Continuity ~
Switch Terminal [ilill]
position A B C D E F
0
1 0 D
2 0 D
: 3 Q ~ f--o
4 0 -0- f---O DBG740ZWB026
DBG740ZWB025
07-40-10
TECHNICAL DATA

HVAC TECHNICAL DATA . ........... 07-50-1
HVAC TECHNICAL DATA

dcf07500000Ow01
Item Specification
REFRIGERANT SYSTEM
Type R-134a
Refrigerant
Regular amount (approx. quantity) (g {oz}) 550 {19.4}
BASIC SYSTEM
Type FD46XG
AlC compressor Lubrication oil Sealed volume
, (approx. (ml {cc, fl oz}) 1BO {1BO, 6.0B}
quantity)
CONTROL SYSTEM
AlC compressor Magnetic clutch clearance (mm {in}) 0.35-0.75 {0.014-0.029}
07-50-1
SERVICE TOOLS
07-60 SERVICE TOOLS

AIR CONDITIONING (HVAC) SST . ... 07-60-1
HEATER, VENTILATION & AIR CONDITIONING (HVAC) SST

dcf076000000w01
8
49 C061 OAOB 49 C061 012 49 C061 013
Gas Charge Set Anti-back flow Gas Leak

valve Tester
~ ~~
dd~
49 H061 005
Attachment
07-60-1
RESTRAINTS
ON-BOARD DIAGNOSTIC. . . . 08-02 AIR BAG SYSTEM .......... 08-10

SYMPTOM SEAT BELT ................ 08-11
TROUBLESHOOTING ...... 08-03 SERVICE TOOLS ........... 08-60

FOREWORD ...................... 08-02-1 DTC 81869, 81870 .................. 08-02-10
AIR 8AG SYSTEM WIRING DIAGRAM DTC 81877, 81878, 81879, 81885 ..... 08-02-12
(ON-80ARD DIAGNOSTiC) ......... 08-02-1 DTC 81881, 81882, 81883, 81886 ..... 08-02-14
DTC DiSPLAy ..................... 08-02-2 DTC 81913, 81916, 81932, 81934 . ... . 08-02-16
CLEARING DTC ................... 08-02-2 DTC 81913, 81925, 81933, 81935 . ... . 08-02-18
DTC TA8LE . ...................... 08-02-3 DTC 81992, 81993, 81994, 81995 ..... 08-02-20
PID/DATA'MONITOR DISPLAY . ....... 08-02-5 DTC 81996, 81997, 81998, 81999 ..... 08-02-22
PID/DATA MONITOR TA8LE ......... 08-02-6 DTC82444,U2017 .................. 08-02-24
DTC 81231 ....................... 08-02-8 DTC 82445, U2018 . ................. 08-02-25
DTC 81317, 81318 ... .............. 08-02-8 DTC 82867 ........................ 08-02-27
DTC 81342 ....................... 08-02-9
FOREWORD
dcf080200000w01
Outline
• The OBD (on-board diagnostic) system has the following functions:
- Malfunction detection function: Detects malfunctions in the air bag system and outputs DTCs.
( - Data monitor function: Reads out specific input/output signals and the system status.
• Diagnostic DTCs can be read/cleared using the current diagnostic tool.
AIR 8AG SYSTEM WIRING DIAGRAM (ON-80ARD DIAGNOSTIC)

dcf080200000w02
POOR CONNECTION
DETECTOR BAR
I }-----{1 k---Fi;;;::j--tW~~;:-' DRIVER-SIDE
AIR BAG
}------{l~-E~~C::::~ MODULE
I------f.i\k::::;-i DRIVER-SIDE PRE-

TENSIONER SEAT
AIR BAG r----i,§.C=::::J BELT
SYSTEM
SAS
WARNING
LIGHT .;t-----<~+----I CONTROL
1-----1§.C==-.J AIR BAG MODULE
i----l'ii:k::::;--, PASSENGER-SIDE
PRE-TENSIONER SEAT
TWISTED PAIR
1-----1!?.C==-.J BELT
1- ............ ..
DRIVER-SIDE A
1 ................ -
r----i.§.C~
PASSENGER-SIDE A
.- ............ ..
SIDE AIR BAG
POOR CONNECTION
SENSOR B 1 ................. -
TWISTED PAIR I DETECTOR BAR
DCF810ZWB001
08-02-1
ON-BOARD DIAGNOSTIC
DTC DISPLAY
dcf080200000w03
UsingWDS
2. Retrieve DTC using the WDS.
DCF802ZWB003
Using IDS/PDS
PDS.
3. Select "Module".
4. Select "RCM".
2. Select "RCM".
DCF802ZWB003
screen.
4. After completion of repairs, clear all DTCs stored in the SAS control module. (See 08-02-2 CLEARING DTC.)
CLEARING DTC
dcf080200000w04
Using WDS
1. After repairs have been made, perform the DTCs reading procedure.
2. Erase DTC using the WDS.
3. Ensure that the customer's concern has been resolved.
Using IDS/PDS
PDS.
3. Select "Module".
4. Select "RCM".
2. Select "RCM".
DCF802ZWB003
screen.
4. Press the clear button on the DTC screen to clear the DTC.
5. Verify that no DTCs are displayed.
08-02-2
ON-BOARD DIAGNOSTIC
DTCTABLE
dcf080200000w05
• OTCs are common for present and past malfunction diagnosis.
Note
• When OTCs not shown in the OTC table are displayed, replace the SAS control module.
• If the air bag system warning light does not illuminate or remains illuminated when the engine switch is
turned to the ON position, inspect and repair the air bag system warning light circuit, and then confirm that
the air bag system warning light is operational.
• The air bag system warning light flashes the OTC pattern for five cycles, and then remains illuminated
until the engine switch is turned to the LOCK position.
OTC
Current Air bag system warning light System malfunction
Page
diagnostic Priority location
tool display Flashing pattern
ranking
UJULJ
SAS control module
(See 08-02-8 DTC
81231 13 3 activation (deployment)
81231.)
control freeze
The SAS control module
Air bag system warning light is illuminated all (See 08-02-8 DTC
81317 - the time
- power supply voltage
81317,81318.)
increases (16.1 V or more)
The SAS control module
Air bag system warning light is illuminated all (See 08-02-8 DTC
81318 - - power supply voltage
the time 81317, 81318.)
decreases (less than 9 V)
81342
12
JLJllLJ 2 SAS control module
(See 08-02-9 DTC
81342.)
SAS control module (air
- the time
1 bag system warning light
DTC 12 is displayed)
Air bag system warning light is illuminated all Air bag system warning
- the time
1
light system circuit open
81869 Air bag system warning
Air bag system warning light dose not
- illuminate
- light system circuit short to (See 08-02-10 DTC
ground 81869, 81870.)
Air bag system warning
81870 - the time
1 light system circuit short to
power supply
Driver-side pre-tensioner
81877 seat belt circuit resistance
high
JUlUlJLJ
Driver-side pre-tensioner (Se~ 08-02-12 DTC
81878 33 10 seat belt circuit short to 81877,81878,
power supply 81879,81885.)
Driver-side pre-tensioner
81879 seat belt circuit short to
ground
Passenger-side pre-
81881 tensioner seat belt circuit
resistance high
IJUlJUU
Passenger-side pre- (See 08-02-14 DTC
81882 34 9 tensioner seat belt circuit 81881,81882,
short to power supply 81883,81886.)
Passenger-side pre-
81883 tensioner seat belt circuit
short to ground.
JUlUlJLJ
Driver-side pre-tensioner (See 08-02-12 DTC
81885 33 10 seat belt circuit resistance 81877, 81878,
low 81879,81885.)
08-02-3
ON-BOARD DIAGNOSTIC
DTC
Page
ranking
Passenger-side pre- (See 08-02-14 DTC
81886 34
I JU1JLJ1JU1J1 9 tensioner seat belt circuit
resistance low
81881,81882,
81883,81886.)
JlJlflJU1illl11
(See 08-02-16 DTC
19 8 81913,81916,
circuit short to body ground
I 81932,81934.)
81913
Passenger-side air bag (See 08-02-18 DTC
21
~ 7 module circuit short to body 81913,81925,
ground 81933,81935.)
JlJlflJU1illl11
Driver-side air bag module (See 08-02-16 DTC
81916 19 8 circuit short to power 81913,81916,
I supply 81932,81934.)

81925 21
~ 7 module circuit short to
power supply
81913,81925,
81933,81935.)
JlJlflJU1illl11
(See 08-02-16 DTC
81932 19 8 81913,81916,
I circuit resistance high
81932,81934.)

81933 21
~ 7 module circuit resistance
high
81913,81925,
81933,81935.)
JlJlflJU1illl11
(See 08-02-16 DTC
81934 19 8 81913,81916,
circuit resistance low
I 81932,81934.)

81935 21
~ 7 module circuit resistance
low
81913,81925,
81933,81935.)
Driver-side side air bag
81992 module circuit short to
power supply
JULJULJ
0
ground (See 08-02-20 DTC

22 12 81992, 81993,
Driver-side side air bag 81994,81995.)
81994 module circuit resistance
high
low
Passenger-side side air bag
power supply
JULJUULJ ground (See 08-02-22 DTC

23 11 81996,81997,
Passenger-side side air bag 81998,81999.)
high
low
82444 43
1DUJU1 6
sensor system (internal
circuit disabled}
(See 08-02-24 DTC
82444, U2017.)
08-02-4
ON-BOARD DIAGNOSTIC
DTC
Page
ranking
(See 08-02-25 DTe
B2445 44 5 sensor system (internal
B2445, U2018.)
circuit disabled)
Poor connection of any

(See 08-02-27 DTe
B2867 4 SAS control module
B2867.)
connectors

(See 08-02-24 DTe
U2017 43 6 sensor (communication
B2444, U2017.)
error)
Passenger-side side air bag (See 08-02-25 DTe

U2018 5 sensor (communication B2445, U2018.)
error)
PID/DATA MONITOR DISPLAY

dcf08020000Dw06
Using WDS
2. Access and monitor PIDs using the WOS.
DCF802ZWB003
Using IDS/PDS
1. Connect the 10S/POS to the OLC-2 connector.
POS .
3. Select "Module".
4. Select "RCM".
2. Select "RCM".
3. Select the applicable PIO from the PIO table.
4. Verify the PIO data according to the directions on the screen.
Note
• The PIO data screen function is used for monitoring the calculated value. Therefore, if the monitored value
of the output parts is not within the specification, inspection of the monitored value of input parts
corresponding to applicable output part control is necessary. In addition, because the system does not
display output part malfunction as abnormality in the monitored value, it is necessary to inspect the output
part individually.
08-02-5
ON-BOARD DIAGNOSTIC
PID/DATA MONITOR TABLE
dcf080200000w07

CONT_RCM - • DTC is detected: 1-255
-
(Number of continuous DTC) • DTC is not detected: 0
CRSH_ST_D1
2Z,2AA
CRSH_ST_D2
2Z,2AA
circuit state)
CRSH_ST_P1
2B,2C
sensor communication state)
CRSH_ST_P2
2B,2C
sensor circuit state)

D_PTENSFLT OPEN • Related wiring harness circuit resistance high: OPEN
(Driver-side pre-tensioner seat SHRT_B+ • Related wiring harness short to power supply: SHRT_B+ 2P,2S
belt circuit state) SHRT_GND • Related wiring harness short to ground: SHRT_GND
DABAGR
(Driver-side air bag module ohm Under any condition: 1.5-3.7 ohms 1S,1V
resistance)
DR_PTENS
(Driver-side pre-tensioner seat ohm Under any condition: 1.5-3.1 ohms 2P,2S
belt resistance)
DS_AB
(Driver-side side air bag ohm Under any condition: 1.4-3.2 ohms 2M, 20
module resistance)
DS_AB_ST SHRT_GND • Related wiring harness short to ground: SHRT_GND
(Driver-side side air bag OPEN • Related wiring harness circuit resistance high: OPEN 2M,20
SHRT_GND • Related wiring harness short to ground: SHRT GND
DS1_STAT SHRT_B+ • Related wiring harness short to power supply: SHRT B+
(Driver-side air bag module OPEN • Related wiring harness circuit resistance high: OPEN 1S,1V
circuit state) SQ_LOWRES • Air bag module circuit resistance low: SQ_LOWRES
DSB_P_ST
(On demand driver-side pre-
OPEN • Related wiring harness circuit resistance high: OPEN
tensioner seat belt circuit
SHRT_B+ • Related wiring harness short to power supply: SHRT_B+ 2P,2S
state)
IG_V_2
V Engine switch to ON position: B+ 1W
(System IG1 voltage value)
OD_CRST_D1
(On demand driver-side side OK! • Sensor normal: OK
2Z,2AA
air bag sensor communication FAULT • Sensor communication error: FAULT
state)
OD_CRST_D2
(On demand driver-side side
2Z,2AA
air bag sensor circuit state)
OD_CRST_P1
2B,2C
side air bag sensor FAULT • Sensor communication error: FAULT
OD_CRST_P2
2B,2C
side air bag sensor circuit FAULT • Sensor internal circuit error: FAULT
state)
08-02-6
ON-BOARD DIAGNOSTIC
PID name (definition) Unit/condition Condition/specification terminal

OD_DAB1_ST SHRT_B+ • Related wiring harness short to power supply: SHRT_B+
(On demand driver-side air OPEN • Related wiring harness circuit resistance high: OPEN 1S,1V
bag module circuit state) SQ_LOWRES • Air bag module circuit resistance low: SQ_LOWRES
OD_DSAB_ST SHRT_GND • Related wiring harness short to ground: SHRT_GND
(On demand driver-side side OPEN • Related wiring harness circuit resistance high: OPEN 2M,20
air bag circuit state) SQ_LOWRES • Air bag module circuit resistance low: SQ_LOWRES
OD_PAB1_ST SHRT_B+ • Related wiring harness short to power supply: SHRT_B+
(On demand passenger-side OPEN • Related wiring harness circuit resistance high: OPEN 1M,1P
air bag module circuit state) SQ_LOWRES • Air bag module circuit resistance low: SQ_LOWRES
OD_PSAB_ST
side air bag sensor circuit
OPEN • Related wiring harness circuit resistance high: OPEN 21,2L
state)
P_PTENSFLT OPEN • Related wiring harness circuit resistance high: OPEN
(Passenger-side pre-tensioner SHRT_B+ • Related wiring harness short to power supply: SHRT_B+ 2G,2J
seat belt circuit state) SHRT_GND • Related wiring harness short to ground: SHRT_GND
PABAGR
(Passenger-side air bag ohm Under any condition: 1.4-2.9 ohms 1M,1P
module resistance)
PS_AB
(Passenger-side side air bag ohm Under any condition: 1.4-3.2 ohms 21,2L
module resistance)
PS_AB_ST SHRT_GND • Related wiring harness short to ground: SHRT_GND
(Passenger-side side air bag OPEN • Related wiring harness circuit resistance high: OPEN 21,2L
sensor circuit state) SQ_LOWRES • Air bag module circuit resistance low: SQ_LOWRES
PS_PTENS
(Passenger-side pre-tensioner ohm Under any condition: 1.5-3.1 ohms 2G,2J
seat belt resistance)
PS1_STAT SHRT_B+ • Related wiring harness short to power supply: SHRT_B+
(Passenger-side air bag OPEN • Related wiring harness circuit resistance high: OPEN 1M,1P
PSB_P_ST
OPEN • Related wiring harness circuit resistance high: OPEN
pre-tensioner seat belt circuit
SHRT_B+ • Related wiring harness short to power supply: SHRT_B+ 2G,2J
state)
08-02-7
ON-BOARD DIAGNOSTIC
DTC 81231
dcf080200000w08
DTC B1231 SAS control module activation (deployment) control freeze

Warning
• Detection conditions are for understanding the DTC outline before performing an inspection .
DETECTION Performing an inspection with only detection conditions may cause injury due to an
operating error, or damage the system. When performing an inspection, always follow the
CONDITION
inspection procedure.
• SAS control module determined collision
ACTION
Replace the SAS control module.
(See 08-10-6 SAS CONTROL MODULE REMOVAUINSTALLATION.)
DTC 81317, 81318

dcf080200000w09
B1317 SAS control module power supply voltage increases (16.1 V or more)
DTC I
I B1318 SAS control module power supply voltage decreases (less than 9 V)
Warning
• Detection conditions are for understanding the DTC outline before performing an inspection.
Performing an inspection with only detection conditions may cause injury due to an
DETECTION
CONDITION
• When the SAS control module power supply voltage is not within 9-16 V.
• Open or short circuit in wiring harness between battery and SAS control module
POSSIBLE • ENGINE 15 A fuse malfunction
CAUSE • Battery malfunction
• SAS control module malfunction
FUSE BLOCK
SAS CONTROL MODULE WIRING

W
~mlxtdABI
W
n ~
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J L~J ~O ~
oom
1vI1S11Pl1MI1J 11GI1011A
1wIH 110 1 11HI1EI1B G3TI~BI ~

C I 0 V Z AE
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1XI1UI1RI 11111FI1C
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o : W IAAbdAGl1
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1 INSPECT FUSE Yes Go to the next step.
• Remove the ENGINE 15 A fuse. No Replace the fuse.
• Is the fuse normal?
2 INSPECT BATTERY Yes Go to the next step.
• Measure the battery positive voltage. No The battery has a malfunction.
• Is the voltage 9 V-16 V? Inspect the charge/discharge system.
3 INSPECT WIRING HARNESS BETWEEN Yes Install the fuse, then go to the next step.
BATTERY AND FUSE BLOCK No Repair the wiring harness between the fuse block and
• Turn the engine switch to the ON position. engine switch.
• Measure the fuse block terminal W voltage.
• Is the voltage 9 V-16 V?
08-02-8
ON-BOARD DIAGNOSTIC

4 INSPECT FUSE BLOCK Yes Replace the SAS control module.
(See 08-10-6 SAS CONTROL MODULE REMOVAU
Warning INSTALLATION.)
• Handling the air bag system No Repair the wiring harness between the fuse block and SAS
components improperly can control module.
accidentally deploy the air bag
modules and pre-tensioner seat belts,
which may seriously injure you. Read
the service warnings and cautions
before handling the air bag system
components.
(See 08-10-2 SERVICE WARNINGS.)
(See 08-10-3 SERVICE CAUTIONS.)

• Disconnect the negative battery cable and
wait for 1 min or more.
• Remove the column cover.
• Disconnect the clock spring connector.
• Remove the glove compartment. (Vehicles
with passenger-side air bag)
• Disconnect the passenger-side air bag
module connector. (Vehicles with passenger-
side air bag)
• Disconnect the driver and passenger-side
seat connectors; (Vehicles with side air bag)
pre-tensioner seat belt connectors. (Vehicle
• Remove the console.
• Disconnect the all SAS control module
connectors.
• Measure the SAS control module terminal
1W voltage.
• Is the voltage 9 V-16 V?
DTC 81342
dcf080200000w10
DTC B1342 SAS control module

Warning
DETECTION
CONDITION
• Malfunction in the SAS control module internal circuit

POSSIBLE
CAUSE
ACTION
Replace the SAS control module.
(See 08-10-6 SAS CONTROL MODULE REMOVAUINSTALLATION.)
08-02-9
ON-BOARD DIAGNOSTIC
DTC 81869, 81870
dcf080200000w11
B1869 Air bag system warning light system circuit open or short to ground
DTC I
I B1870 Air bag system warning light system circuit short to power supply
Warning
CONDITION
• Malfunction in air bag system warning light circuit

• METER 15 A fuse malfunction
POSSIBLE • Malfunction of connectors between instrument cluster and SAS control module
CAUSE • Open or short circuit in wiring harness between METER 15 A fuse and instrument cluster
• Open or short circuit in wiring harness between instrument cluster and SAS control module
INSTRUMENT CLUSTER
SAS CONTROL MODULE
101 t J 1m
10 1M 11K 11 11G 1E 11C 1A
J n ~
-
I'"'::::::-:::::J
-
1P iN 11L 1J 11H iF 110 1B
1V 11S11PI1MI1JI1GI1011A
"'" \:;
1wl1T 110 I 11HI1EI1B

rr ;:::::><:: T 1xl1Ul1RI 11111FI1C
2wl2U 12S 20120 2MI2K 2112G 2EI2CI2A
2X 12V 12T 2RI2P 2NI2L 2J 12H 2FI2DI2B
I~~ I
I~~ I
1 INSPECT METER 15 A FUSE Yes Reinstall the METER 15 A fuse, then go to the next step.
• Turn engine switch to LOCK position. No Replace the METER 15 A fuse.
• Disconnect the negative battery cable.
• Remove the METER 15 A fuse.
• Is fuse normal?
2 INSPECT FOR CONTINUITY BETWEEN Yes Go to the next step.
METER 15 A FUSE AND INSTRUMENT No Repair the wiring harness.
CLUSTER
• Connect the negative battery cable.
• Measure voltage at instrument cluster
connector terminal 2C.
• Is voltage 9 V or more?
08-02-10
ON-BOARD DIAGNOSTIC

INSTRUMENT CLUSTER AND SAS CONTROL No Replace the air bag wiring harness.
MODULE
Warning
• Handling the air bag system
components improperly can
components.
• Turn the engine switch to LOCK position.
• Remove the glove compartment. (Vehicles
with passenger-side air bag)
side air bag)
.
seat connectors. (Vehicles with side air bag)
connectors.
• Disconnect the instrument cluster.
• Inspect following wiring harness between
SAS control module and instrument cluster
terminals for short to ground, short to power
supply, and open circuit:
-H-1H
• Is wiring harness normal?
4 INSPECT AIR BAG SYSTEM WARNING LIGHT Yes Go to the next step.
• Connect instrument cluster. No Replace the instrument cluster.
• Turn the engine switch to ON position. y (See 09-22-2 INSTRUMENT CLUSTER REMOVAU
• Is air bag system warning light illuminated? INSTALLATION.)
5 INSPECT AIR BAG SYSTEM WARNING LIGHT Yes Go to the next step.
• Using a jumper wire, cause a short circuit No Replace the instrument cluster.
between instrument cluster terminal 1Hand (See 09-22-2 INSTRUMENT CLUSTER REMOVAU
ground. INSTALLATION. )
• Does air bag system warning light go out?
6 INSPECT AIR BAG SYSTEM WARNING LIGHT Yes The system is normal at present. (Clear the malfunction
• Turn the engine switch to LOCK position. from the memory.)
• Disconnect the negative battery cable and No, Replace the SAS control module.
wait for 1 min or more. (See 08-10-6 SAS CONTROL MODULE REMOVAU
• Connect the all SAS control module INSTALLATION.)
connectors.
• Connect the driver and passenger-side pre-
tensioner seat belt connectors. (Vehicle with
pre-tensioner seat belt)
• Connect the driver and passenger-side seat
connectors. (Vehicles with side air bag)
• Connect the passenger-side air bag module
connector. (Vehicles with passenger-side air
bag)
• Connect the clock spring connector.
• Turn the engine switch to ON position.
• Verify that the air bag system warning light
turns off approx. 2 5 after illuminating for
approx. 6 s.
• Is the result normal?
08-02-11
ON-BOARD DIAGNOSTIC
DTCB1877,B1878,B1879,B1885
dcf080200000w12
B1877 Driver-side pre-tensioner seat belt system resistance high

B1878 Driver-side pre-tensioner seat belt system circuit short to power supply
DTC
B1879 Driver-side pre-tensioner seat belt system circuit short to ground
B1885 Driver-side pre-tensioner seat belt system resistance low
Warning
DETECTION operating error, or damage the system. When performing an inspection, always follow the
CONDITION inspection procedure.
• Resistance other than 1.5-3.1 ohms detected in driver-side pre-tensioner seat belt circuit
• Malfunction in the wiring harness between driver-side pre-tensioner seat belt and SAS control module
• Open or short circuit in wiring harness between driver-side pre-tensioner seat belt and SAS control
POSSIBLE module
CAUSE • Driver-side pre-tensioner seat belt malfunction

DRIVER-SIDE PRE-TENSIONER SEAT BELT
/n I I ~
~
2Y 2V I 2S I 2P I 2M I 2J I 2G I 20 I 2A
2Z 2WI2T 1 12H 1 2E 12B
I
I I
2AA 2X 2U 2R 20 I I 2L I 21 I 2F I 2C
I~~
I~~ I
1 INSPECT DRIVER-SIDE PRE-TENSIONER Yes Replace the SAS control module.
SEAT BELT (See 08-10-6 SAS CONTROL MODULE REMOVAU
• Using the current diagnostic tool, verify the INSTALLATION.)
following PID/DATA monitor. No Go to the next step.
(See 08-02-6 PID/DATA MONITOR TABLE.)
-DR_PTENS
• Is the resistance of the driver-side pre-
tensioner seat belt normal?
- Resistance: 1.5-3.1 ohms
2 INSPECT DRIVER-SIDE PRE-TENSIONER Yes Replace the air bag wiring harness.
SEAT BELT CONNECTOR No Go to the next step.
Warning
components.

• Disconnect the driver-side pre-tensioner seat
belt connector.
• Is there any malfunction of the driver-side
pre-tensioner seat belt connector?
08-02-12
ON-BOARD DIAGNOSTIC

DRIVER-SIDE PRE-TENSIONER SEAT BELT No Replace the driver-side pre-tensioner seat belt.
OR RELATED WIRING HARNESS (See 08-10-5 SIDE AIR BAG MODULE REMOVAU
• Connect leads of SST (Fuel and INSTALLATION.)
thermometer checker) or apply 2-ohm
resistor to driver-side pre-tensioner seat belt
connector terminal A and B.
• Set resistance of SST (Fuel and
thermometer checker) to the 2-ohm position.
• Are DTCs B1877, B1878, B1879, and/or
B1885 indicated?
DRIVER-SIDE PRE-TENSIONER SEAT BELT No Replace the air bag wiring harness.
MODULE AND SAS CONTROL MODULE
belt connector.
• Disconnect the SAS control module
connectors.
• Inspect the wiring harness between SAS
control module terminal 2S and driver-side
pre-tensioner seat belt terminal A, SAS
control module terminal 2P and driver-side
pre-tensioner seat belt terminal B for the
following:
- Short to ground
- Short to power supply
- Open circuit
• Is the wiring harness normal?
5 INSPECT AIR BAG SYSTEM WARNING LIGHT Yes Replace the SAS control module.
• Connect the all SAS control module (See 08-10-6 SAS CONTROL MODULE REMOVAU
connectors. INSTALLATION.)
• Connect the driver and passenger-side pre- No The system is normal at present. (Clear the malfunction
tensioner seat belt connectors. from the memory.)
B1885 indicated?
08-02-13
ON-BOARD DIAGNOSTIC
DTCB1881,B1882,B1883,B1886
dcf080200000w13
B1881 Passenger-side pre-tensioner seat belt circuit resistance high

B1882 Passenger-side pre-tensioner seat belt circuit short to power supply
DTC
B1883 Passenger-side pre-tensioner seat belt circuit short to body ground
B1886 Passenger-side pre-tensioner seat belt circuit resistance low
Warning
Performing an inspection according to only the detection conditions may cause injury due to
DETECTION an operating error, or damage the system. When performing an inspection, always follow the
• Resistance other than 1.5-3.1 ohms detected in passenger-side pre-tensioner seat belt circuit
• Malfunction in wiring harness between passenger-side pre-tensioner seat belt and SAS control module
• Open or short circuit in wiring harness between passenger-side pre-tensioner seat belt and SAS control
POSSIBLE module
CAUSE • Passenger-side pre-tensioner seat belt malfunction

HARNESS·SIDE CONNECTOR PASSENGER-SIDE PRE-TENSIONER SEAT BELT
/n I J ~
I 2G I 20 I 2A
~
2Y 2V 1 2S 1 2P 12M 1 2J
2Z 2wI2T 1 12H 12E 12B

2AA 2X I 2U I 2R I 20 I 2L I 21 I 2F I 2C
I~~I
I~~ I
1 INSPECT PASSENGER-SIDE PRE- Yes Replace the SAS control module.
TENSIONER SEAT BELT (See 08-10-6 SAS CONTROL MODULE REMOVAU
INSTALLATION.)
• Using the current diagnostic tool, verify the
-PS_PTENS
• Is the resistance of the passenger-side pre-
tensioner seat belt normal?
2 INSPECT PASSENGER-SIDE PRE- Yes Replace the air bag wiring harness.
TENSIONER SEAT BELT CONNECTOR No Go to the next step.
Warning
- components.

• Disconnect the passenger-side pre-tensioner
seat belt connector.
• Is there any malfunction of the passenger-
side pre-tensioner seat belt connector?
08-02-14
ON-BOARD DIAGNOSTIC

PASSENGER-SIDE PRE-TENSIONER SEAT No Replace the passenger-side pre-tensioner seat belt.
BELT OR RELATED WIRING HARNESS (See 08-10-5 SIDE AIR BAG MODULE REMOVAU
• Connect the leads of the SST (Fuel and INSTALLATION.)
thermometer checker} or apply 2-ohm
resistance to passenger-side pre-tensioner
seat belt connector terminals A and B.
• Set the resistance of the SST (Fuel and
• Are DTCs B 1881, B 1882, B 1883, and/or
B 1886 indicated?
PASSENGER-SIDE PRE-TENSIONER SEAT No Replace the air bag wiring harness.
BELT MODULE AND SAS CONTROL
MODULE
connector.
connectors.
control module terminal 2J and passenger-
side pre-tensioner seat belt terminal A, SAS
control module terminal 2G and passenger-
side pre-tensioner seat belt terminal B for the
following:
- Short to ground
- Open circuit
tensioner seat belt connectors. from the memory.)
• Are DTCs B 1881, B 1882, B 1883, and/or
B 1886 indicated?
08-02-15
ON-BOARD DIAGNOSTIC
DTCB1913,B1916,B1932,B1934
dcf080200000w14
B1913 Driver-side air bag module system circuit short to ground

B1916 Driver-side air bag module system circuit short to power supply
DTC
B1932 Driver-side air bag module system resistance high
B1934 Driver-side air bag module system resistance low
Warning
DETECTION operating error, or damage the system. When performing an inspection, always follow the
• resistance other than 1.5-3.7 ohms detected in driver-side air bag module circuit
• Malfunction in wiring harness between driver-side air bag module and SAS control module
• Open or short circuit in wiring harness between clock spring and SAS control module
POSSIBLE • Clock spring malfunction
CAUSE • Driver-side air bag module malfunction

HARNESS-SIDE CONNECTOR DRIVER-SIDE AIR BAG MODULE WIRING
CLOCK SPRING WIRING HARNESS-SIDE CONNECTOR
HARNESS-SIDE CONNECTOR (CLOCK SPRING)
I n I~J ~
S~[B
~
1vI1S11P 1MI1JI1GI1DI1A
1WIH 110 11HI1EI1B

1xI1UI1R 11111FI1C
I~' I I~'I I~' I

1 INSPECT DRIVER-SIDE AIR BAG MODULE Yes Replace the SAS control module.
• Using the current diagnostic tool, verify the (See 08-10-6 SAS CONTROL MODULE REMOVAU
following PID/DATA monitor. INSTALLATION.)
(See 08-02-6 PID/DATA MONITOR TABLE.) No Go to the next step.
-DABAGR
• Is the resistance of the driver-side air bag
module normal?
2 INSPECT DRIVER-SIDE AIR BAG MODULE Yes Replace the air bag wiring harness and/or clock spring.
CONNECTOR (CLOCK SPRING) No Go to the next step.
Warning
components.

• Disconr,ect the negative battery cable and
• Remove the driver-side air bag module.
• Is there any malfunction of the driver-side air
bag module connector?
08-02-16
ON-BOARD DIAGNOSTIC

DRIVER-SIDE AIR BAG MODULE OR No Replace the driver-side air bag module.
RELATED WIRING HARNESS (See 08-10-4 DRIVER-SIDE AIR 8AG MODULE
• Connect the leads of SST (Fuel and REMOVAUINSTALLATION.)
resistance to driver-side air bag module
connector terminals 3A and 38.
• Set the resistance of SST (Fuel and
thermometer checker) to 2-ohm position.
• Are DTCs 81913,81916,81932 and/or
81934?
4 INSPECT CLOCK SPRING Yes Go to the next step.
• Inspect the clock spring. No Replace the clock spring.
(See 08-10-8 CLOCK SPRING (See 08-10-7 CLOCK SPRING REMOVAUINSTALLATION.)
INSPECTION.)
• Is the clock spring normal?
CLOCK SPRING AND SAS CONTROL No Replace the air bag wiring harness.
MODULE
• Remove the glove compartment.
side air bag)
connectors.
control module terminal 1S and clock spring
terminal1A, SAS control module terminal1V
and clock spring terminal 18 for the
following:
- Short to ground
- Open circuit
tensioner seat belt connectors. (Vehicle with from the memory.)
connectors. (Vehicles with side air bag)
connector. (Vehicles with passenger-side air
bag)
• Are DTCs 81913,81916,81932 and/or
81934?
08-02-17
ON-BOARD DIAGNOSTIC
DTCB1913,B1925,B1933,B1935
dcf080200000w15
B1913 Passenger-side air bag module circuit short to ground

B1925 Passenger-side air bag module circuit short to power supply
DTC
B1933 Passenger-side air bag module circuit resistance high
B1935 Passenger-side air bag module circuit resistance low
Warning
DETECTION
an operating error, or damage the system. When performing an inspection, always follow the
CONDITION
• Resistance other than 1.4-2.9 ohms detected in passenger-side air bag module circuit
• Malfunction in wiring harness between passenger-side air bag module and SAS control module
• Open or short circuit in wiring harness between passenger-side air bag module and SAS control
POSSIBLE module
CAUSE • Passenger-side air bag module malfunction
I n I "::::><::: I~
PASSENGER-SIDE AIR BAG MODULE WIRING
1vl1S11PI1MI1J 11GI1DI1A
1wlnl1Q1
1xl1U11RI
11HI1EI1B
11111FI1C
~mij
I~~ I I~~I
1 INSPECT PASSENGER-SIDE AIR BAG Yes Replace the SAS control module.
MODULE (See 08-10-6 SAS CONTROL MODULE REMOVAU
-PABAGR
• Is the resistance of the passenger-side air
bag module normal?
2 INSPECT PASSENGER-SIDE AIR BAG Yes Replace the air bag wiring harness.
MODULE CONNECTOR No Go to the next step.
Warning
components.
• Turn the engine switch to the LOCI( position.

module connector.
side air bag module connector?
08-02-18
ON-BOARD DIAGNOSTIC

PASSENGER-SIDE AIR BAG MODULE OR No Replace the passenger-side air bag module.
RELATED WIRING HARNESS (See 08-10-5 PASSENGER-SIDE AIR BAG MODULE
• Connect the leads of the SST (Fuel and REMOVAUINSTALLATION.)
resistance to passenger-side air bag module
• Are DTCs B1913, B1925, B1933 and/or
B 1935 indicated?
PASSENGER-SIDE AIR BAG MODULE AND No Replace the air bag wiring harness.
SAS CONTROL MODULE
module connector.
connectors.
control module terminal 1P and passenger-
side air bag module terminal A, SAS control
module terminal 1M and passenger-side air
bag module terminal B for the following:
- Short to ground
- Open circuit
• Connect the passenger-side air bag module No The system is normal at present. (Clear the malfunction
connector. from the memory.)
B1935 indicated?
08-02-19
ON-BOARD DIAGNOSTIC
DTCB1992,B1993,B1994,B1995
dcf080200000w16
B1992 Driver-side side air bag module circuit short to power supply
B1993 Driver-side side air bag module circuit short to ground
DTC
B1994 Driver-side side air bag module circuit resistance high
B1995 Driver-side side air bag module circuit resistance low
Warning
• Resistance other than 1.4-3.2 ohms detected in driver-side side air bag module circuit
• Malfunction in wiring harness between driver-side side air bag module and SAS control module
• Open or short circuit in wiring harness between driver-side side air bag module and SAS control
POSSIBLE module
CAUSE • Driver-side side air bag module malfunction

DRIVER-SIDE SIDE AIR BAG MODULE
/n I J ~
2Y 2V 12S 1 2P 12M-I 2J 12G 120 12A
2Z 2wI2TI 12H 12E 12B

2AA 2X 1 2U 1 2R 1 20 1 2L 1 21 1 2F 1 2C
~
I~~ I I~~ I
1 INSPECT DRIVER-SIDE SIDE AIR BAG Yes Replace the SAS control module.
-DS_AB
• Is the resistance of the driver-side side air
bag module normal?
2 INSPECT DRIVER-SIDE SIDE AIR BAG Yes Replace the air bag wiring harness.
Warning
components.

• Remove the driver-side side air bag module.
• Disconnect the driver-side side air bag
module connector.
side air bag module connector?
08-02-20
ON-BOARD DIAGNOSTIC

DRIVER-SIDE SIDE AIR BAG MODULE OR No Replace the driver-side side air bag module.
RELATED WIRING HARNESS (See 08-10-5 SIDE AIR BAG MODULE REMOVAU
thermometer checker} or apply 2-ohm
resistance to driver-side side air bag module
B1995 indicated?
DRIVER-SIDE SIDE AIR BAG MODULE AND No Replace the air bag wiring harness.
SAS CONTROL MODULE
module connector.
connectors.
control module terminal 2M and driver-side
side air bag module terminal A, SAS control
module terminal 20 and driver-side side air
bag module terminal B for the following:
- Short to ground
- Open circuit
• Connect the driver-side side air bag module No The system is normal at present. (Clear the malfunction
connector. from the memory.)
B1995 indicated?
08-02-21
ON-BOARD DIAGNOSTIC
DTCB1996,B1997,B1998,B1999
dcf080200000w17
B1996 Passenger-side side air bag module circuit short to power supply
B1997 Passenger-side side air bag module circuit short to ground
DTC
B1998 Passenger-side side air bag module circuit resistance high
B1999 Passenger-side side air bag module circuit resistance low
Warning
• Detection conditions are for understanding the DTC outline before performing an inspection •
• Resistance other than 1.4-3.2 ohms detected in passenger-side side air bag module circuit
• Malfunction in wiring harness between passenger-side side air bag module and SAS control module
• Open or short circuit in wiring harness between passenger-side side air bag module and SAS control
POSSIBLE module
CAUSE • Passenger-side side air bag module malfunction

PASSENGER-SIDE SIDE AIR BAG MODULE
/n I I J)~
2Y 2V I 2S 12P 12M I 2J I 2G I 20 I 2A
2Z 2wI2T I 12H 12E 12B

2AA 2X I 2U I 2R I 20 I 2L I 21 I 2F I 2C
~
IGt, I I~'I
1 INSPECT PASSENGER-SIDE SIDE AIR BAG Yes Replace the SAS control module.
-PS_AB
• Is the resistance of the passenger-side side
air bag module normal?
2 INSPECT PASSENGER-SIDE SIDE AIR BAG Yes Replace the air bag wiring harness.
Warning
components.
• Remove the passenger-side side air bag
module.
• Disconnect the passenger-side side air bag
module connector.
side side air bag moduie connector?
08-02-22
ON-BOARD DIAGNOSTIC

PASSENGER-SIDE SIDE AIR BAG MODULE No Replace the passenger-side side air bag module.
OR RELATED WIRING HARNESS (See 08-10-5 SIDE AIR BAG MODULE REMOVAU
resistance to passenger-side side air bag
module connector terminals A and B.
B 1999 indicated?
PASSENGER-SIDE SIDE AIR BAG MODULE No Replace the air bag wiring harness.
AND SAS CONTROL MODULE
module connector.
connectors.
control module terminal 2L and passenger-
side side air bag module terminal A, SAS
control module terminal 21 and passenger-
side side air bag module terminal B for the
following:
- Short to ground
- Open circuit
• Connect the passenger-side side air bag No The system is normal at present. (Clear the malfunction
module connector. from the memory.)
B1999 indicated?
08-02-23
ON-BOARD DIAGNOSTIC
DTC 82444, U2017
dcf080200000w18
B2444 Driver-side side air bag sensor system internal circuit disabled
DTC~~~-+~-----~_____~~~~----------~~---------------~~----------------------------------------------------------------------~
U2017 Driver-side side air bag sensor system communication error
Warning
• Malfunction in wiring harness between driver-side side air bag sensor and SAS control module
• Malfunction in driver-side side air bag sensor circuit
• Open or short circuit in wiring harness between driver-side side air bag sensor and SAS control module
POSSIBLE
• Driver-side side air bag sensor malfunction
CAUSE

DRIVER-SIDE SIDE AIR BAG SENSOR
1 INSPECT DRIVER-SIDE SIDE AIR BAG Yes Replace the air bag wiring harness.
Warning
components.

sensor connector.
side air bag sensor connector?
08-02-24
ON-BOARD DIAGNOSTIC

2 INSPECT WIRING HARNESS BETWEEN Yes Replace the driver-side side air bag sensor, then go to the
DRIVER-SIDE SIDE AIR BAG SENSOR AND next step.
SAS CONTROL MODULE (See 08-10-6 SIDE AIR BAG SENSOR REMOVAU
• Turn the engine switch to the LOCK position. INSTALLATION.)
• Disconnect the negative battery cable and No Replace the air bag wiring harness.
connector.
sensor connector.
• Inspect the wiring harnesses between SAS
control module terminal 2AA and driver-side
side air bag sensor terminal A, SAS control
module terminal 2Z and driver-side side air
bag sensor terminal B for the following:
- Short to ground
- Open circuit
3 INSPECT SAS CONTROL MODULE Yes Replace the SAS control module.
• Connect the SAS control module connector. (See 08-10-6 SAS CONTROL MODULE REMOVAU
• Connect the driver-side side air bag sensor INSTALLATION.)
connector. No DTC troubleshooting completed.
• Are DTCs B2444, U2017 indicated?
DTC 82445, U2018

dcf080200000w19
B2445 Passenger-side side air bag sensor system internal circuit disabled
DTC~~~~~--~~~~~~~----~~------~~------------------------~
U2018 Passenger-side side air bag sensor system communication error
Warning
• Malfunction in wiring harness between passenger-side side air bag sensor and SAS control module
• Malfunction in passenger-side side air bag sensor circuit
• Open or short circuit in wiring harness between passenger-side side air bag sensor and SAS control
POSSIBLE module
CAUSE • Passenger-side side air bag sensor malfunction

PASSENGER-SIDE SIDE AIR BAG SENSOR
08-02-25
ON-BOARD DIAGNOSTIC
1 INSPECT PASSENGER-SIDE SIDE AIR BAG Yes Replace the air bag wiring harness.
Warning
components.

sensor connector.
side side air bag sensor connector?
2 INSPECT WIRING HARNESS BETWEEN Yes Replace the passenger-side side air bag sensor, then go
PASSENGER-SIDE SIDE AIR BAG SENSOR to the next step.
AND SAS CONTROL MODULE (See 08-10-6 SIDE AIR 8AG SENSOR REMOVAU
• Turn the engine switch to the LOCK position. INSTALLATION.)
• Disconnect the negative battery cable and No Replace the air bag wiring harness.
connector.
sensor connector.
• Inspect the wiring harnesses between SAS
control module terminal 2C and passenger-
side side air bag sensor terminal A, SAS
control module terminal 28 and passenger-
side side air bag sensor terminal 8 for the
following:
- Short to ground
- Open circuit
3 INSPECT SAS CONTROL MODULE Yes Replace the SAS control module.
• Connect the SAS control module connector. (See 08-10-6 SAS CONTROL MODULE REMOVAU
• Connect the passenger-side side air bag INSTALLATION.)
sensor connector. No DTC troubleshooting completed.
• Are DTCs 82445, U2018 indicated?
08-02-26
ON-BOARD DIAGNOSTIC
DTC 82867
dcfOB020000Ow20
DTC B2867 SAS control module connector poor connection

Warning
CONDITION operating error, or damage the system. When performing an inspection, always follow the
• There is no continuity between poor connection detector bar terminals of SAS control module.
POSSIBLE • Poor connection of any SAS control module connectors
• Malfunction of any SAS control module connectors
CAUSE

I n I I ~ /n L >< J ~
1V 11S11Pl1MI1J 11GI1DI1A 2Y 2vI2S12PI2MI2JI2GI2DI2A
1wln 11Q 1 11HI1EI1B 2Z 2wI2TI 12HI2EI2B

1XI1UI1RI 1 11 11FI1C 2M 2X 12U 12R 1201 2L 1 21 12F 12C
I~~ I I~~I
VERIFY THAT ALL SAS CONTROL MODULE Yes Go to the next step.
CONNECTORS ARE CONNECTED WITH SAS No Reconnect connector properly.
CONTROL MODULE
Warning
components.
• Turn engine switch to LOCK position.

• Are all SAS control module connectors
securely connected?
08-02-27
ON-BOARD DIAGNOSTIC

2 INSPECT ALL SAS CONTROL MODULE Yes Replace the SAS control module.
CONNECTORS (See 08-10-6 SAS CONTROL MODULE REMOVAU
• Remove the column cover. INSTALLATION.)
• Disconnect the clock spring connector. No Replace wiring harnesses.
module connector.
side air bag module connectors. (Vehicles
with side air bag)
connectors.
• Are poor connection detector bars of all SAS
control module connectors normal?
08-02-28
08-03 SYMPTOM TROUBLESHOOTING

AIR BAG SYSTEM ................. 08-03-1 NO.1 AIR BAG SYSTEM WARNING
AIR BAG SYSTEM WIRING DIAGRAM LIGHT DOES NOT ILLUMINATE ...... 08-03-1
(SYMPTOM TROUBLESHOOTING) ... 08-03-1 NO.2 AIR BAG SYSTEM WARNING
LIGHT ILLUMINATES
CONSTANTLY .................... 08-03-3
AIR BAG SYSTEM

dcf080300000w01
Troubleshooting Index
• Use the chart below verify the symptoms of the trouble in order to diagnose the appropriate area.
No. Troubleshooting item Description Page
1 Air bag system warning light does not Malfunction in air bag system warning (See 08-03-1 NO.1 AI R BAG SYSTEM
illuminate. light circuit (short to ground). WARNING LIGHT DOES NOT
ILLUMINATE)
2 Air bag system warning light is Malfunction in air bag system warning (See 08-03-3 NO.2 AIR BAG SYSTEM
illuminated constantly. light circuit (open circuit or short to WARNING LIGHT ILLUMINATES
power supply). CONSTANTLY)
AIR BAG SYSTEM WIRING DIAGRAM (SYMPTOM TROUBLESHOOTING)

dcf080300000w02
CLOCK SPRING
~
POOR CONNECTION
DETECTOR BAR
I 1-----f1 k---t~~6.fi(R=:::;-J DRIVER-SIDE
AIR BAG
1----{1~-t=~~~::::::..J MODULE
l----ro;;=::::;-lDRIVER-SIDE PRE-
TENSIONER SEAT
AIR BAG
r----I.~:::::::J BELT
SYSTEM
SAS
WARNING
LIGHT ..;t---~-+----I CONTROL
t----Wl=:::J AIR BAG MODULE
PASSENGER-SIDE
PRE-TENSIONER SEAT
TWISTED PAIR
r----I.!?C:::::::J BELT
,--------
DRIVER-SIDE A
I ............... ..
r---1.§.C=~
,--------
PASSENGER-SIDE A
SIDE AIR BAG
I
POOR CONNECTION
SENSOR B 1 .................. -
DETECTOR BAR
TWISTED PAIR
DCF810ZWB001
NO.1 AIR BAG SYSTEM WARNING LIGHT DOES NOT ILLUMINATE

dcf08030000OW03
1 Air bag system warning light does not illuminate.

DETECTION Malfunction in air bag system warning light circuit (short to ground)
CONDITION
POSSIBLE • SAS control module malfunction

CAUSE • Instrument cluster (circuit board) malfunction
• Short to ground circuit in wiring harness between instrument cluster and SAS control module
08-03-1
• When performing an asterisked (*) troubleshooting inspection, slightly shake the wiring harness and
connectors while performing the inspection to discover whether poor contact points are the cause of any
intermittent malfunction. If there is a problem, verify that connectors, terminals and wiring harness are
1 INSPECT OTHER WARNING AND INDICATOR Yes Turn the engine switch to the LOCK position, then go to the
LIGHTS CIRCUIT IN INSTRUMENT CLUSTER next step.
• Turn the engine switch to the ON position. No Inspect instrument cluster power supply system and ground
• Do other warning and indicator lights system the, then go to Step 4.
illuminate?
2 INSPECT SAS CONTROL MODULE Yes Replace the SAS control module, then go to Step 4.
Warning (See 08-10-6 SAS CONTROL MODULE REMOVAU
• Handling the air bag system INSTALLATION.)
components improperly can No Go to the next step.
the air bag system service warnings
and cautions before handling the air
bag system components.
module connector.
seat connectors.
• Disconnect the driver- and passenger-side
pre-tensioner seat belt connectors.
• Disconnect all SAS control module
connectors.
• Does the air bag system warning light
illuminate?
*3 INSPECT WIRING HARNESS BETWEEN SAS Yes Replace the wiring harness, then go to Step 4.
CONTROL MODULE AND INSTRUMENT No Replace the instrument cluster, then go to the next step.
CLUSTER FOR SHORT TO GROUND (See 09-22-2 INSTRUMENT CLUSTER REMOVAU
• Turn the engine switch to LOCK position. INSTALLATION. )
• Disconnect the negative battery cable.
• Is there continuity between terminal 1H of
the instrument cluster connector and
ground?
4 CONFIRM THAT MALFUNCTION SYMPTOMS Yes Complete troubleshooting, then explain repairs to customer.
• Turn the engine switch to LOCK position. malfunction recurs.
• Connect all SAS control module connectors.
• Connect the driver and passenger-side
connectors.
connector.
operate properly?
08-03-2
NO.2 AIR BAG SYSTEM WARNING LIGHT ILLUMINATES CONSTANTLY
dcf08030000Ow04
2 Air bag system warning light is illuminated constantly.

DETECTION Malfunction in air bag system warning light circuit (open circuit or short to power supply).
CONDITION
• Weak battery
• Instrument cluster (circuit board) malfunction
• No connection in SAS control module connector
.POSSIBLE • Poor contact in instrument cluster connector (16-pin)
CAUSE • Open or short to power supply circuit in wiring harness between instrument cluster and SAS control
module
• Poor contact at terminals 1X and/or 1W of SAS control module connector
• Poor contact in wiring harness between terminal 1X of SAS control module connector and ground
• Poor contact in wiring harness between battery and terminal 1W of SAS control module
• When performing an asterisked (*) troubleshooting inspection, slightly shake the wiring harness and
connectors while performing the inspection to discover whether poor contact points are the cause of any
intermittent malfunction. If there is a problem, verify that connectors, terminals and wiring harness are
INSPECT BATTERY Yes Go to the next step.
• Measure the voltage of battery. No Battery is weak.
• Is the voltage 9 V or more? Inspect charge/discharge system, then go to Step 9.
(See 01-17-2 BATTERY INSPECTION.)
2 VERIFY THAT SAS CONTROL MODULE Yes Go to the next step.
CONNECTOR IS CONNECTED No Reconnect the connector properly, then go to Step 9.
Warning
the air bag system service warnings
and cautions before handling the air

• Are all SAS control module connectors
securely connected?
*3 INSPECT WIRING HARNESS BETWEEN SAS Yes Go to the next step.
CONTROL MODULE AND INSTRUMENT No Replace the wiring harness, then go to Step 9.
CLUSTER FOR CONTINUITY
module connector.
seat connectors.
• Disconnect the driver- and passenger-side
• Disconnect all SAS control module
connectors.
• Is there continuity between SAS control
module connector (20-pin) terminal 1T and
instrument cluster connector terminal 1H?
08-03-3

*4 INSPECT WIRING HARNESS BETWEEN SAS Yes Replace the wiring harness, then go to Step 9.
CONTROL MODULE AND INSTRUMENT No Go to the next step.
CLUSTER FOR SHORT TO POWER SUPPLY
• Measure the voltage at instrument cluster
connector terminal 1H.
• Is the voltage 9 V or more?
5 CHECK TO SEE WHETHER MALFUNCTION Yes Replace the instrument cluster, then go to Step 9.
IS IN AIR BAG SYSTEM WARNING LIGHT IN (See 09-22-2 INSTRUMENT CLUSTER REMOVAU
INSTRUMENT CLUSTER INSTALLATION.)
• Connect instrument cluster connector No Go to the next step.
terminal 1H to ground, then reconnect the
connector
illuminate with engine switch ON?
6 INSPECT POWER SUPPLY CIRCUIT OF SAS Yes Go to the Step 8.
CONTROL MODULE (TERMINAL (20-pin) 1W) No Go to the next step.
connectors.
connector.
• Inspect the voltage for PID/DATA monitor
"IG_V_2" item using current diagnostic tool.
• Is the voltage of at least one terminal 9 V or
more?
BATTERY AND FUSE BLOCK No Repair the wiring harnesses, then go to Step 9.
• Measure the voltage at instrument cluster
connector terminal 2A.
• Is the voltage 9 V or more?
8 VERIFY THAT SAS CONTROL MODULE Yes Replace the SAS control module, then go to the next step.
CONNECTOR TERMINAL 1X IS GROUND (See 08-10-6 SAS CONTROL MODULE REMOVAU
• Turn the engine switch to LOCK position. INSTALLATION.)
• Disconnect the negative battery cable and No Replace the wiring harnesses, then go to the next step.
module connector.
side air bag module connectors.
• Disconnect all SAS control module control
model connectors.
control module connector (20-pin) terminal
1X and ground for the following:
- Open circuit
08-03-4

9 CONFIRM THAT MALFUNCTION SYMPTOMS Yes Complete troubleshooting, then explain repairs to customer.
• Turn the engine switch to LOCK position. malfunction recurs.
connectors.
connector.
• Connect the instrument cluster connector.
operate properly?
08-03-5
AIR BAG SYSTEM
08-10 AIR BAG SYSTEM

LOCATION INDEX .................. 08-10-1 CLOCK SPRING
SERVICE WARNINGS ............... 08-10-2 REMOVAUINSTALLATION ......... . 08-10-7
SERVICE CAUTIONS . .............. 08-10-3 CLOCK SPRING ADJUSTMENT ....... 08-10-7
DRIVER-SIDE AIR BAG MODULE CLOCK SPRING INSPECTION ........ 08-10-8
REMOVAUINSTALLATION .......... 08-10-4 AIR BAG MODULE AND
PASSENGER-SIDE AIR BAG MODULE PRE-TENSIONER SEAT BELT
REMOVAUINSTALLATION . ......... 08-10-5 DEPLOYMENT PROCEDURES . ..... . 08-10-9
SIDE AIR BAG MODULE AIR BAG MODULE AND
REMOVAUINSTALLATION . ......... 08-10-5 PRE-TENSIONER SEAT BELT
SAS CONTROL MODULE REMOVAU DISPOSAL PROCEDURES .......... 08-10-18
INSTALLATION ................... 08-10-6 INSPECTION OF SST
SIDE AIR BAG SENSOR (DEPLOYMENT TOOL) ............ . 08-10-19
REMOVAUINSTALLATION . ......... 08-10-6
LOCATION INDEX
dcf081000000w01
DCF810ZWB100
1 Driver-side air bag module 4 Pre-tensioner seat belt

(See 08-10-4 DRIVER-SIDE AIR BAG MODULE (See 08-10-9 AIR BAG MODULE AND
REMOVAUINSTALLATION.) PRE-TENSIONER SEAT BELT DEPLOYMENT
(See 08-10-9 AIR BAG MODULE AND PROCEDURES.)
PRE-TENSIONER SEAT BELT DEPLOYMENT 5 SAS control module
PROCEDURES.) (See 08-10-6 SAS CONTROL MODULE
2 Passenger-side air bag module REMOVAUINSTALLATION.)
(See 08-10-5 PASSENGER-SIDE AIR BAG 6 Side air bag sensor
MODULE REMOVAUINSTALLATION.) (See 08-10-6 SIDE AIR BAG SENSOR REMOVAU
(See 08-10-9 AIR BAG MODULE AND INSTALLATION.)
PRE-TENSIONER SEAT BELT DEPLOYMENT
7 Clock spring
PROCEDURES.)
(See 08-10-7 CLOCK SPRING REMOVAU
3 Side air bag module INSTALLATION.)
(See 08-10-5 SIDE AIR BAG MODuLE REMOVAU (See 08-10-8 CLOCK SPRING INSPECTION.)
INSTALLATION.) (See 08-10-7 CLOCK SPRING ADJUSTMENT.)
(See 08-10-9 AIR BAG MODULE AND
PRE-TENSIONER SEAT BELT DEPLOYMENT
PROCEDURES.)
08-10-1
AIR BAG SYSTEM
SERVICE WARNINGS
dcf081000000w02
Air Bag Module Inspection

• Inspecting an air bag module using a tester
can operate (deploy) the air bag module, NO GOOD
which may cause serious injury. Do not use a
tester to inspect an air bag module. Always
use the on-board diagnostic function to
diagnose the air bag module for malfunctions.
DPE810ZW1002
Air Bag Module Handling

• Before removing the air bag module or disconnecting the air bag module connector, always turn the
ignition switch to the LOCK position, disconnect the negative battery cable, and then wait for 1 min or
more to allow the backup power supply of the SAS control module to deplete its stored power.
• Handling a live (undeployed) air bag module
that is pOinted toward your body could result
in serious injury if the air bag module were to
accidentally operate (deploy). When carrying
a live (undeployed) air bag module, point the
deployment surface away from your body to
lessen the chance of injury in case it operates
(deploys).
GOOD NO GOOD
DPE810ZW1003
• A live (undeployed) air bag module placed

with its deployment surface to ground is GOOD NO GOOD
dangerous. If the air bag module were to
accidentally operate (deploy), it could cause
serious injury. Always place a live
(undeployed) air bag module with its
deployment surface up.
DPE81 OZW1 004
Side Air Bag Module Handling

• When a side air bag module operates (deploys) due to a collision, the interior of the seat back (pad,
frame, trim) may become damaged. If a side air bag does not operate (deploy) normally from a seat
back that has been reused, a serious accident may result. After a side air bag has operated (deployed),
always replace both the side air bag module and the seat back (pad, frame, trim) with new parts. After
servicing, verify that the seat operates normally and that the wiring harness is not caught.
SAS control module Handling
• Removing the SAS control module or disconnecting the SAS control module connector with the
ignition switch at the ON position can activate the sensor in the SAS control module and operate
(deploy) the air bags and pre-tensioner seat belts, which may cause serious injury. Before removing the
SAS control module or disconnecting the SAS control module connector, always turn the ignition
switch to the LOCK position, disconnect the negative battery cable, and then wait for 1 min or more to
allow the backup power supply of the SAS control module to deplete its stored power.
• Connecting the SAS control module connector with the SAS control module not securely fixed to the
vehicle is dangerous. The sensor in the SAS control module could send an electrical signal to the air
bag modules and pre-tensioner seat belts. This will operate (deploy) the air bags and pre-tensioner
seat belts, which may result in serious injury. Therefore, before connecting the connector, securely fix
the SAS control module to 'the vehicle.
08-10-2
AIR BAG SYSTEM
• Because a sensor is built into the SAS control module, once the air bags and pre-tensioner seat belts
have operated (deployed) due to a collision or other causes, the SAS control module must be replaced
with a new one even if the used one does not have any visible external damage or deformation. The
used SAS control module may have been damaged internally which may cause improper operation. If
the SAS control module is reused, the air bags and pre-tensioner seat belts may not operate (deploy)
normally, which could result in a serious accident. Always replace the SAS control module with a new
one. The SAS control module cannot be bench-checked or self-checked.
Side Air Bag Sensor Handling

• Removing the side air bag sensor or disconnecting the side air bag sensor connector with the ignition
switch at the ON position can activate the side air bag sensor and operate (j:leploy) the side air bag,
which may cause serious injury. Before removing the side air bag sensor or disconnecting the side air
bag sensor connector, always turn the ignition switch to the LOCK position, disconnect the negative
battery cable, and then wait for 1 min or more to allow the backup power supply of the SAS control
module to deplete its stored power.
• If the side air bag sensor is subjected to shock or the sensor is disassembled, the side air bag may
accidentally operate (deploy) and cause injury, or the system may fail to operate normally and cause a
serious accident. Do not subject the side air bag sensor to shock or disassemble the sensor.
• Because a sensor is built into the side air bag sensor, once the air bag has operated (deployed) due to
a collision or other causes, the side air bag sensor must be replaced with a new one even if the used
one does not have any visible external damage or deformation. If the side air bag sensor is reused, the
side air bag may not operate (deploy) normally, which could result in a serious accident. Always
replace the side air bag sensor with a new one. The side air bag sensor cannot be bench-checked or
self-checked.
Pre-tensioner Seat Belt Inspection

• Inspecting a pre-tensioner seat belt using a
tester can operate (deploy) the pre-tensioner
seat belt, which may cause serious injury. Do
not use a tester to inspect a pre-tensioner
seat belt. Always use the on-board diagnostic
function to diagnose the pre-tensioner seat
belt for malfunctions.
NO GOOD
E5U810ZW5005
SERVICE CAUTIONS
dcf081000000w03
Air Bag System Component Disassembly

• Disassembling the air bag system
components could cause it to not operate
(deploy) normally. Never disassemble any air
DPE81 OZW1 005
l.
08-10-3
AIR BAG SYSTEM
Air Bag Module, Pre-tensioner Seat Belt Handling
• Oil, grease, or water on the air bag modules may cause the air bags and pre-tensioner seat belts to fail
to operate (deploy) in an accident. Never allow oil, grease, or water to get on the air bag modules or
pre-tensioner seat belts.
• Inserting a screwdriver or similar object into
the connector of an air bag module or a pre-
tensioner seat belt may damage the connector
and cause the air bag module or the pre-
tensioner seat belt to operate (deploy)
improperly, which may cause serious injury.
Never insert any foreign objects into the air
bag module or seat belt connectors.
NO GOOD NO GOOD
DCF810ZWB002
Air Bag Module, Pre-tensioner Seat Belt Reuse

• Even if an air bag module or a pre-tensioner seat belt does not operate (deploy) in a collision and does
not have any external signs of damage, it may have been damaged internally, which may cause
improper operation. Before reusing a live (undeployed) air bag module and the pre-tensioner seat belts,
always use the on-board diagnostic to diagnose the air bag module and the pre-tensioner seat belts to
verify that they have no malfunction.
Air Bag Wiring Harness Repair

• Incorrectly repairing an air bag wiring harness
can accidentally operate (deploy) the air bag
module and pre-tensioner seat belts. If a
problem is found in the air bag wiring
harness, always replace the wiring harness
with a new one.
NO GOOD
CHU0810W606
DRIVER-SIDE AIR BAG MODULE REMOVAUINSTALLATION

dcf081 05701 OwOl
Warning
seriously injure you. Read the service warnings and cautions before handling the air bag module.
(See 08-10-2 SERVICE WARNINGS.) (See 08-10-3 SERVICE CAUTIONS.)
1. Turn the engine switch to the LOCK position.

2. Disconnect the negative battery cable and wait for 1 min or more. (See 01-17-2 BATTERY REMOVAL!
INSTALLATION.)
1 Bolt
2 Connector
(See 08-10-5 Connector Removal Note.)
3 Driver-side air bag module

6. Verify that the air bag system warning light
illuminates for approx. 6 s and goes out.
• If the air bag system warning light does not
operate, refer to the on-board diagnostic DCF8l0ZWB012
system (air bag system) and perform \
inspection of the system.
08-10-4
AIR BAG SYSTEM
Connector Removal Note
1. Using a flathead screwdriver, pry out the
connector stopper plate.
2. Disconnect the connector.
CHU0810W003
PASSENGER-SIDE AIR BAG MODULE REMOVAUINSTALLATION
dcf081057050w01
Warning
seriously injure you. Read the service warnings and cautions before handling the air bag module.
(See 08-10-2 SERVICE WARNINGS.) (See 08-10-3 SERVICE CAUTIONS.)
2. Disconnect the negative battery cable and wait for 1 min or more. (See 01-17-2 BATTERY REMOVAU
INSTALLATION.)
1 Connector
2 Bolt
3 Passenger-side air bag module
5. Install in the reserve order of removal.

operate, refer to the on-board diagnostic
system (air bag system) and perform DCF810ZWB013
SIDE AIR BAG MODULE REMOVAUINSTALLATION

dcf081000147w01
Warning
• Handling the air bag module improperly can accidentally operate (deploy) the air bag module,
which may seriously injure you. Read the service warnings and cautions before handling the air
bag module. (See 08-10-2 SERVICE WARNINGS.) (See 08-10-3 SERVICE CAUTIONS.)
• If the side air bag module is installed with debris in the seat back, the foreign material may be
scattered when the side air bag module operates (deploys), causing injury. Verify that there is no
foreign material in the seat back before installing the side air bag module.
INSTALLATION.)
. 3. Remove in the order indicated in the table.
1 Cup
2 Bolt
3 Side air bag module
4 Connector

operate, refer to the on-board diagnostic DCF810ZWB014
system (air bag system) and perform

08-10-5
AIR BAG SYSTEM
SAS CONTROL MODULE REMOVAUINSTALLATION
dcf081057030w01
Warning
• Handling the SAS control module improperly can accidentally deploy the air bag modules and pre-
tensioner seat belt, which may seriously injure you. Read the service warnings and cautions
before handling the air bag module. (See 08-10-2 SERVICE WARNINGS.) (See 08-10-3 SERVICE
CAUTIONS.)

2. Disconnect the negative battery cable and wait for 1 min or more. (See 01-17-2 BATTERY REMOVAL/
INSTALLATION.)
3. Remove the console. (See 09-17-12 CONSOLE REMOVAL/INSTALLATION.)
4. Remove in the order indicated in the table. . - - - - - - 3 - - - - - - - 2 - 6 - . 9 - - 9 . - 8-N.-m-------,
1 Connector {70-99 kgf.cm,

61-86 in·lbf}
2 Bolt
3 SAS control module

system (air bag system) and perform DCF810ZWB015
SIDE AIR BAG SENSOR REMOVAUINSTALLATION

dcf081000146w01
Warning
• Handling the side air bag sensor improperly can accidentally operate (deploy) the air bag module,
which may seriously injure you. Read the service warnings and cautions before handling the side
air bag sensor. (See 08-10-2 SERVICE WARNINGS.) (See 08-10-3 SERVICE CAUTIONS.)

2. Disconnect the negative battery cable and wait for 1 min or more. (See 01-17-2 BATTERY REMOVAL/
INSTALLATION.)
1 Bolt A
2 Cover
3 Connector
4 Bolt B
5 Side air bag sensor

5. Turn the engine switch to the ON position and
hold for 5 s or more.
DCF810ZWB016
operate, refer to the on-board diagnostic system (air bag system) and perform inspection of the system.
08-10-6
AIR BAG SYSTEM
CLOCK SPRING REMOVAL/INSTALLATION
dcf081066123w01
INSTALLATION.)
2. Remove the driver-side air bag module. (See OS-10-4 DRIVER-SIDE AIR BAG MODULE REMOVAU
INSTALLATION.)
3. Remove the steering wheel. (See 06-14-6 STEERING WHEEL AND COLUMN REMOVAUINSTALLATION.)
4. Remove the column cover. (See 09-17-S COLUMN COVER REMOVAUINSTALLATION.)
5. Remove in the order indicated in the table. ~
1 Screw
2 Connector
3 Clock spring
(See 08-10-7 Clock Spring Installation Note.)

7. Turn the ignition switch to the ON position.
S. Verify that the air bag system warning light
operate, refer to the on-board diagnostic DCF81 OZWB01 0
Clock Spring Installation Note
Caution
• If the clock spring is not adjusted, the spring wire in the clock spring could over-wind and break
when the steering wheel is turned. Always adjust the clock spring after installing it.
1. Adjust the clock spring after installing it. (See OS-10-7 CLOCK SPRING ADJUSTMENT.)
CLOCK SPRING ADJUSTMENT

dcf081066123w02
Note
• The adjustment procedure is also specified on the caution label of the clock spring.
1. Set the front tires straight-ahead.
Caution
• The clock spring will break if over-wound. Do not forcibly turn the clock spring.
2. Turn the clock spring clockwise until it stops.
08-10-7
AIR BAG SYSTEM
3. From the stopped position, turn the clock spring
counterclockwise 2 3/4 turns.
4. Align the mark on the clock spring with the mark

on the outer housing.
CLOCK SPRING INSPECTION

dcf081066123w03
1. Verify that the continuity is as indicated in the table.

• If not as indicated in the table, replace the clock spring.
Note
• When the vehicle-side connector for the clock spring is disconnected, terminals 1A and 1B are shorted to
prevent unexpected operation (deployment) of the air bag module.
0-0 : Continuity
Terminal
Test condition
1A 18 20 3A 38 40
0 '-0
Under any
condition 0 0
0 0
DCF810ZWB006
VEHICLE-SIDE CONNECTOR AIR BAG MODULE-SIDE CONNECTOR
AlB
+
AlB HORN s~s I ~2~=ctT! ~ I ~ IH4~rt?HI
I~~I I~~I
DCF810ZWB007
08-10-8
AIR BAG SYSTEM
AIR BAG MODULE AND PRE-TENSIONER SEAT BELT DEPLOYMENT PROCEDURES
dcf08105700Ow01
Warning
• A live (undeployed) air bag module or pre-tensioner seat belt may accidentally operate (deploy)
when it is disposed of and cause serious injury. Do not dispose of a live (undeployed) air bag
module and pre-tensioner seat belt. If the SSTs (Deployment tool and Adapter harness) are not
available, consult the nearest Mazda representative for assistance.
Caution
• Deploying the air bag modules and pre-tensioner seat belts inside the vehicle may cause damage
to the vehicle interior. When the vehicle is not to be scrapped, always deploy the air bag modules
and pre-tensioner seat belts outside the vehicle.
• If the vehicle is to be scrapped, or when disposing of any air bag modules or pre-tensioner seat belts, operate
(deploy) them inside the vehicle by following the deployment procedure below and using the SST (Deployment
tool) .
• When disposing of an operated (deployed) air bag module and pre-tensioner seat belt, refer to "AIR BAG
MODULE AND PRE-TENSIONER SEAT BELT DISPOSAL PROCEDURES".
Deployment Procedure for Inside of Vehicle

1. Inspect the SST (Deployment tool). (See 08-10-19 INSPECTION OF SST (DEPLOYMENT TOOL).)
2. Move the vehicle to an open space, away from strong winds, and close all of the vehicle doors and windows.
INSTALLATION.)
5. Follow the procedure below for operating (deploying) the applicable air bag module or pre-tensioner seat belt.
Driver-side Air Bag Module

1. Remove the driver-side air bag module. (See 08-10-4 DRIVER-SIDE AIR BAG MODULE REMOVAU
INSTALLATION.)
2. Connect the SST (Adapter harness) to the driver-
side air bag module as shown in the figure.
3. Install the driver-side air bag module. (See 08-10-
4 DRIVER-SIDE AIR BAG MODULE REMOVAU
INSTALLATION.)
DCF810ZWB017
4. Connect the SST (Deployment tool) to the SST

(Adapter harness).
5. Connect both SST (Deployment tool) to the
battery. Connect the power supply red clip to the
positive battery terminal, and the black clip to the
negative battery terminal.
6. Verify that the red lamp on both SST (Deployment
tool) is illuminated. ©
7. Verify that all persons are standing at least 6 m
{20 ft} away from the vehicle.
~. , •• I I
CPJ810ZWB032
08-10-9
AIR BAG SYSTEM
8. Press the activation switch on the SST
(Deployment tool) to operate (deploy) the driver- ~. I •• I I
side air bag module.
ACTIVATION
SWITCH
Warning
• The air bag module is very hot
immediately after it is operated
(deployed). You can get burned. Do not
touch the air bag module for at least 15
min after deployment.
9. Disconnect the SST (Deployment tool) from the

A6E8130W028
SST (Adapter harness).
Passenger-side Air Bag Module

2. Disconnect the passenger-side air bag module connector.
3. Connect the SST (Adapter harness) to the I--------============::::;;;:::~::J
passenger-side air bag module as shown in the
figure.
PASSENGER-SIDE AIR
BAG MODULE
CONNECTOR

(Adapter harness).
5. Connect the SST (Deployment tool) to the battery.
Connect the power supply red clip to the positive
battery terminal, and the black clip to the negative
battery terminal.
DCF810ZWB008

(Deployment tool) to operate (deploy) the :I' I •• II
passenger-side air bag module.
ACTIVATION
SWITCH
Warning
immediately after. it is operated
(deployed). You can be burned. Do not

A6E8130W028
08-10-10
AIR BAG SYSTEM
Side Air Bag Module
1. Disconnect the seat connector.
2. Connect the SST (Adapter harness) to the side
air bag module as shown in the figure.
DCF810ZWB019

(Adapter harness).
battery terminal.
5. Verify that the red lamp on the SST (Deployment
DCF810ZWB008

(Deployment tool) to operate (deploy) the side air
bag module.
ACTIVATION
SWITCH
Warning

A6E8130W028
Pre-tensioner Seat Belt

1. Remove the pre-tensioner seat belt and connect
the SST (Adapter harness) as shown in the
figure. (See 08-11-1 SEAT BELT REMOVAL!
INSTALLATION.)
2. Install the pre-tensioner seat belt.
E5U810ZW5026
08-10-11
AIR BAG SYSTEM
(Adapter harness).
battery terminal.
~. I •• I I
B3E0810W027

(Deployment tool) to operate (deploy) the pre- ~. I •• I I
tensioner seat belt.
ACTIVATION
SWITCH
Warning

A6E8130W028
Deployment Procedure for Outside of Vehicle

1. Inspect the SST (Deployment tool).
(See 08-10-19 INSPECTION OF SST (DEPLOYMENT TOOL).)
3. Disconnect the negative battery cable and wait for 1 min or more. (See 01-17-2 BATTERY REMOVAL!
INSTALLATION.)
4. Follow the procedure below for operating (deploying) the applicable air bag module or pre-tensioner seat belt.
Driver-side Air Bag Module

1. Remove the driver-side air bag module. (See 08-10-4 DRIVER-SIDE AIR BAG MODULE REMOVAL!
INSTALLATION.)
2. Connect the SST (Adapter harness) to the driver-
side air bag module as shown in the figure.
DCF810ZWB017
3. Place the driver-side air bag module on the center

of the tire wheel with the padded surface facing DRIVER-SIDE AIR BAG MODULE
up. To secure the air bag module to the tire wheel,
wrap a wire (cross section 1.25 mm 2 {O.002 in 2 }
WIRE
or more) through the wheel and the bolt
installation holes of the air bag module at least 4
times.
Warning
• If the air bag module is not properly
installed to the tire wheel, serious injury
may occur when the module is operated
(deployed). When installing the air bag DCF810ZWB020
module to the tire wheel, make sure the

padded surface is facing up.
08-10-12
AIR BAG SYSTEM
4. Stack three tires without wheels on top of the tire
with the driver-side air bag module, and then TIRE WITH
WHEEL
stack another tire with a wheel on the very top.
TIRE
WITHOUT
WHEEL
TIRE WITH
DRIVER-SIDE
AIR BAG
MODULE
DPE81 OZWl 036
5. Secure the tires with wire.
A6E8130W034

(Adapter harness).
tool) is illuminated.
CPJ810ZWB034

(Deployment tool) to operate (deploy) the driver- :I. I •• ' I
side air bag module.
ACTIVATION
SWITCH
Warning

08-10-13
AIR BAG SYSTEM
Passenger-side Air Bag Module
1. Remove the passenger-side air bag module. (See 08-10-5 PASSENGER-SIDE AIR BAG MODULE REMOVAU
INSTALLATION.)
2. Place the padded surface of the passenger-side
air bag module facing the center of the tire as
shown in the figure. To secure the air bag module
to the tire wheel, wrap a wire (cross section 1.25
mm 2 {O.002 in 2 } or more) through the tire and
the bolt installation holes of the air bag module at
least 4 times. TIRE
PASSENGER-SIDE
Warning AIR BAG MODULE
secured to the tire, the tires may fall over
by the impact of operation (deployment) DCF810ZWB021
and cause serious injury. To prevent this,
secure the air bag module properly with
the padded surface facing the center of the tire.
3. Connect the SST (Adapter harness) to the

passenger-side air bag module as shown in the
figure.
DCF810ZWB022
4. Stack the tire with the passenger-side air bag

module on top of two tires without wheels. Stack a TIRE WITH
tire without a wheelan top of the tire with the WHEEL
passenger-side air bag module, and then stack
another tire with a wheelan the very top.
TIRE
WITHHOUT
TIRE WITH WHEEL
PASSENGER-SIDE
AIR BAG MODULE
DCF810ZWB023
A6E8130W034
08-10-14
AIR BAG SYSTEM
(Adapter harness).
DCF810ZWB024

(Deployment tool) to operate (deploy) the ~. I •• I t
passenger-side air bag module. ACTIVATION
SWITCH
Warning

A6E8130W028
Side Air Bag Module

1. Remove the side air bag module. (See 08-10-5 SIDE AIR BAG MODULE REMOVAUINSTALLATION.)
2. Connect the SST (Adapter harness) to the side
air bag module as shown in the figure.
SIDE AIR BAG

MODULE
DCF810ZWB025
3. Place the padded surface of the side air bag

module facing the center of the tire as shown in
the figure. To secure the air bag module to the tire
wheel, wrap a wire (cross section 1.25 mm 2
{O.002 in 2 } or more) through the tire and around
the bracket at least 4 times.
Warning
secured to the tire, the tires may fall over
by the impact of operation (deployment)
and cause serious injury. To prevent this, DCF810ZWB026
secure the air bag module properly with
the padded surface facing the center of the tire.
08-10-15
AIR BAG SYSTEM
4. Stack the tire with the side air bag module on top
of two tires without wheels. Stack a tire without a
wheel on top of the tire with the side air bag
module, and then stack another tire with a wheel
on the very top.
TIRE WITH TIRE
SIDE AIR BAG WITHOUT
MODULE WHEEL
DPE810ZW1037
A6E8130W034

(Adapter harness).
l~
battery terminal.
8. Verify that the red lamp on the SST (Deployment 1
B3E0810W027

(Deployment tool) to operate (deploy) the side air ~. I •• I t
bag module. .
ACTIVATION
SWITCH
Warning

A6E8130W028
08-10-16
AIR BAG SYSTEM
Pre-tensioner Seat Belt
1. Remove the pre-tensioner seat belt. (See 08-11-1 SEAT BELT REMOVAUINSTALLATION.)
2. Connect the SST (Adapter harness) to the pre-
tensioner seat belt as shown in the figure.
:.. , .. 'I
E5U810ZW5026
3. Put the pre-tensioner seat belt inside the tire and

secure it to the tire by wrapping a wire (cross
section of 1.25 mm2 {O.002 in 2 } or more)
through the tire and the bolt installation holes at
least 4 times.
Warning
• If the pre-tensioner seat belt is not
properly secured to the tire, serious
injury may occur when the pre-tensioner PRE-TENSIONER
part is deployed. When installing the pre- SEAT BELT
tensioner seat belt to the tire, make sure DPE81 OZW1 033
the pre-tensioner part is inside the tire.
4. Stack the tire with the pre-tensioner seat belt on

TIRE WITH
top of two tires without wheels. Stack a tire
WHEEL
without a wheelan top of the tire with the pre- TIRE
tensioner seat belt, and then stack another tire WITHOUT
with a wheelan the very top. WHEEL
TIRE WITH
PRE-TENSIONER
SEAT BELT
DPE810ZW1034
A6E8130W034
08-10-17
AIR BAG SYSTEM
(Adapter harness).
battery terminal.
DPE81 OZW1 035

(Deployment tool) to operate (deploy) the pre- ~. • •• I I
tensioner seat belt.
ACTIVATION
SWITCH
Warning

A6E8130W028
AIR BAG MODULE AND PRE-TENSIONER SEAT BELT DISPOSAL PROCEDURES

dcf081057000w02
Warning
• A live (undeployed) air bag module or pre-tensioner seat belt may accidentally operate (deploy)
when it is disposed of and cause serious injury. Always refer to the "AIR BAG MODULE AND PRE-
TENSIONER SEAT BELT DEPLOYMENT PROCEDURES" and dispose of air bag modules and pre-
tensioner seat belts in a deployed condition.
• The air bag modules and the pre-tensioner seat belts are very hot immediately after they are
deployed. You can be burned. Do not touch an air bag module and pre-tensioner seat belt for at
least 15 min after deployment.
• Pouring water on the deployed air bag module and pre-tensioner seat belt is dangerous. The water
will mix with the residual gases to form a gas that can make breathing difficult. Do not pour water
on the deployed air bag module and pre-tensioner seat belt.
• The deployed air bag module or pre-tensioner seat belt may contain deposits of sodium
hydroxide, a caustic byproduct of the gas-generated combustion. If this substance gets into your
eyes or on your hands, it can cause irritation and itching. When handling the deployed air bag
module and pre-tensioner seat belt, wear gloves and safety glasses.
1. Remove the deployed air bag module or pre-tensioner seat belt.

2. Put the air bag module or pre-tensioner seat belt ,.-,-----------=--=::---------------,
in a plastic bag, seal the bag, and then dispose of
it.
BHJ0810W023
08-10-18
AIR BAG SYSTEM
INSPECTION OF SST (DEPLOYMENT TOOL)
dcf081 001 o78w01
1. Before using the SST (49 H066 002), inspect its

operation.
Inspection Procedure
1. Follow the steps below to inspect the SST (49 H066 002) .
• If not as indicated in the table, replace the SST (49 H066 002) because it has a malfunction.
Warning
• Do not use a malfunctioning SST (49 HOGG 002), otherwise it could cause the air bag module or
pre-tensioner seat belt to accidentally operate (deploy).
Caution
• Because the permissible voltage for the SST (49 HOGG 002) is 12 V, do not connect a 24 V power
source because it will damage the SST. Always connect only a 12 V power source.
Light condition
Step Inspection procedure
Green Red
Connect the power supply
red clip to the positive
1 battery terminal, and the On Off
black clip to the negative
battery terminal.
Connect connectors A and
2 Off On
B. BLACK CLIP
3 Press the activation switch. On Off
ACTIVATION
SWITCH
CONNECTOR B
08-10-19
SEAT BELT
08-11 SEAT BELT

LOCATION INDEX .................. 08-11-1 ADJUSTER ANCHOR
SEAT BELT REMOVAUINSTALLATION .......... 08-11-5
REMOVAUINSTALLATION .......... 08-11-1 SEAT BELT INSPECTION ............ 08-11-6
BUCKLE REMOVAUINSTALLATION ... 08-11-7
LOCATION INDEX
dcf081157000w01
BENCH SEAT
DCF811ZWB100
Seat belt 2 Center seat belt

(See 08-11-1 SEAT BELT REMOVAU (See 08-11-1 SEAT BELT REMOVAU
(See 08-11-5 ADJUSTER ANCHOR REMOVAU 3 Buckle
INSTALLATION. ) (See 08-11-7 BUCKLE REMOVAUINSTALLATION.)
(See 08-11-6 SEAT BELT INSPECTION.)
SEAT BELT REMOVAUINSTALLATION

dcf081157630w01
Warning
• Handling the seat belt (pre-tensioner seat belt) improperly can accidentally deploy the pre-
tensioner seat belt, which may seriously injure you. Read the service warnings and cautions
before handling the seat belt (pre-tensioner seat belt). (See 08-10-2 SERVICE WARNINGS.) (See 08-
10-3 SERVICE CAUTIONS.)
Caution
• The ELR (emergency locking retractor) has a spring that will unwind if the retractor cover is
removed. The spring cannot be rewound by hand. If this occurs, the ELR will not work properly.
Therefore, do not disassemble the retractor.
06-11-1
SEAT BELT
Regular Cab (Driver-side and passenger-side)
1. Turn the engine switch to the LOCK position. (vehicle with pre-tensioner seat belt)
2. Disconnect the negative battery cable and wait for 1 min or more. (vehicle with pre-tensioner seat belt) (See
01-17-2 BATTERY REMOVAL/INSTALLATION.)
3. Remove the anchor cover.
ANCHOR COVER
1 Connector (vehicle with pre-tensioner seat belt)
(See 08-11-2 Connector removal note.)
2 Bolt UPPER ANCHOR
BOLT
3 Seat belt
39-78 {3.9-8.0,
29-57}
4. Remove the upper anchor bolt.
5. Remove the B-pillar trim. (See 09-17-15 B-
PILLAR TRIM REMOVAL/INSTALLATION.)
(vehicle with pre-tensioner seat belt)
illuminates for approx. 6 s and goes out. (vehicle
DCF811ZWB001
Connector removal note

1. Using a screwdriver, pry out the pre-tensioner
seat belt connector stopper plate.
E5U811ZW5003
Regular Cab (center)

I 1 IBolt ~ 39-78 {3.9-8.0,

l 29-57}
2. Install in the reverse order of removal. 2
DCF811 ZWB002
08-11-·2
SEAT BELT
Stretch Cab (with rear access system)
01-17 -2 BATTERY REMOVAUINSTALLATION.)
3. Remove the bezel. ANCHOR
4. Remove the anchor cover. COVER
5. Remove the upper anchor bolt and lower anchor
bolt. UPPER
6. Remove the Rear access panel trim. (See 09-17- ANCHOR
18 REAR ACCESS PANEL TRIM REMOVAU BOLT
INSTALLATION.) 39-79
{3.9-8.0, REAR
7. Remove the seat belt through the seat belt hole.
29-57} ACCESS
PANEL
SEAT BELT
BEZEL
ANCHOR
COVER
LOWER ANCHOR BOLT ~..:-::;~><:::===s>
39-79 {3.9-8.0, 29-57}
DCF811 ZWB006

seat belt connector stopper plate. (vehicle with
9. Remove the bolts from the retractor.
10. Remove the retractor.

11. Install in the reverse order of removal. 7.8-10.8 N·m
{0.8-1.1 kgf·cm,
5.9-7.9 in·lbf}
BOLT __ ~f"'"
RETRACTOR
SEAT BELT
BOLT

DCF811 ZWB007
08-11-3
SEAT BELT
Double Cab
Front
01-17-2 BATTERY REMOVAL/INSTALLATION.)
(1) Rear scuff plate (See 09-17-21 REAR SCUFF PLATE REMOVAUINSTALLATION.)
(2) Rea'r seat back (See 09-13-5 REAR SEAT REMOVAUINSTALLATION.)
(3) Rear seat belt upper anchor installation bolt (See 08-11-5 Rear)
(4) Remove the C-pillar trim (See 09-17-17 C-PILLAR TRIM REMOVAUINSTALLATION.)
(5) Front scuff plate (See 09-17-20 FRONT SCUFF PLATE REMOVAUINSTALLATION.)
(6) Remove the B-pillar lower trim (See 09-17-16 B-PILLAR LOWER TRIM REMOVAUINSTALLATION.)
(7) Front seat belt upper anchor cover
(8) Front seat belt upper anchor installation bolt
(9) Remove the B-pillar upper trim (See 09-17-16 B-PILLAR UPPER TRIM REMOVAUINSTALLATION.)
1 Lower anchor cover
UPPER ANCHOR BOLT
39-78 {3.9-8.0, ' \ . II
2 Connector (vehicle with pre-tensioner seat belt) 29-57} l ~ ~
UPPERANCHOR~~ ~\~
(See 08-11-2 Connector removal note.)
3 Bolt -""
4 Seat belt COVER _

(vehicle with pre-tensioner seat belt)
illuminates for approx. 6 s and goes out. (vehicle
DBG811 ZWBA02
Connector removal note

seat belt connector stopper plate.
08-11-4
SEAT BELT
Rear
(2) Rear seat back (See 09-13-5 REAR SEAT REMOVAUINSTALLATION.)
(3) Rear seat belt upper anchor cover
(4) Rear seat belt upper anchor installation bolt
I 1 IBolt ANCHOR COVER
7.8~10.8~
{O.8-1.1 kgf·cm,
5.9-7.9 in·lbf}
DBG811ZWBA01
ADJUSTER ANCHOR REMOVAL/INSTALLATION

dcf081157630w02
(2) Rear seat back (See 09-13-5 REAR SEAT REMOVAUINSTALLATION.)
(3) Rear seat belt upper anchor installation bolt (See 08-11-5 Rear)
(5) Front scuff plate (See 09-17-20 FRONT SCUFF PLATE REMOVAUINSTALLATION.)
!
(6) Remove the B-pillar lower trim (See 09-17-16 B-PILLAR LOWER TRIM REMOVAUINSTALLATION.)
(7) Front seat belt upper anchor installation bolt (See 08-11-4 Front)
(8) Remove the B-pillar upper trim (See 09-17-16 B-PILLAR UPPER TRIM REMOVAUINSTALLATION.)
12 ., Ri:~,~e in the order indicated in 'he table. i.J 1
2 Adjuster anchor
1 39-78
{3.9-8.0,
29-57}

DCF811ZWB004
08-11-5
SEAT BELT
SEAT BELT INSPECTION
dcf08115700Ow02
Belt
1. Verify that the belt is installed properly with no twists or kinks.
2. Verify that there is no damage to the seat belt and no deformation of the metal fittings.
• If there is any malfunction, replace the seat belt.
ELR
1. Verify that the belt can be pulled out smoothly,
and that it retracts smoothly.
• If there is any malfunction, replace the seat
belt.
2. Verify that the retractor locks when the belt is
pulled quickly.
belt.
3. Remove the retractor.
DCF811 ZWB008
4. While pulling the seat belt out, make sure that the
seat belt does not lock when the retractor is tilted
slowly up to 15° from the mounted position and
locks when the retractor is tilted 40° or more.
belt.
B3E0811 W009
Load Limiter Retractor
Warning
• When the load limiter operates, the belt and anchor rub against each other strongly leaving wear
tracks. If the seat belt is used in this state, the seat belt will not function at its full capability and
there is the possibility of serious injury to passengers. Be sure to replace the seat belt once the
load limiter operates.
1. If the vehicle has been subjected to a shock in an

accident, pull the belt from the retractor and
confirm that there are no wear tracks (the load
limiter has not operated) by visually inspecting ANCHOR
and feeling the belt.
belt.
TRACE
OF WEAR
B3E0811W010
08-11-6
SEAT BELT
BUCKLE REMOVAUINSTALLATION
dcf08115762Ow01
Bench Seat (Driver-side and Passenger-side)

I 1 IBolt .-. ?
~
39-78 {3.9-B.O,
29-57}
2 Buckle

k~,I, ....,--r-::-:----r------.f
DCF811 ZWBOl 0
Bench Seat (Center)

1. Remove the seat. (See 09-13-2 SEAT REMOVAUINSTALLATION.)
2. Remove in the order indicated in the table. r-----------------------,
CD~ \
I 1 IBolt 39-7B {3.9-B.O,
29-57} >&
DCF811ZWB011
Separate Seat
1. Remove the seat or front seat. (See 09-13-2 SEAT REMOVAUINSTALLATION.) (See 09-13-4 FRONT SEAT
2. Remove the side cover. (See 09-13-3 SEAT DISASSEMBLY/ASSEMBLY.) (See 09-13-4 FRONT SEAT
I 1
2
IBolt
Buckle

39-78N·m
{3.9-B.O kgf·m,
29-57 ft·lbf}
Double Cab
Rear
I 1 IBolt

DCF811ZWB012
08-11-7
SERVICE TOOLS
08-60 SERVICE TOOLS

RESTRAINTS SST ................. 08-60-1
RESTRAINTS SST
dcf08600000OwO 1
49 H066 002 490066002 49 L066 002
Deployment tool Adapter Adapter

~~~ harness harness
49 N088 OAO
Fuel and
Thermometer
checker
08-60-1
BODY & ACCESSORIES
ON-BOARD DIAGNOSTIC SYMPTOM

[IMMOBILIZER SYSTEM] ... 09-02A TROUBLESHOOTING
ON-BOARD DIAGNOSTIC [AUDIO] ................. 09-03D
[AUDIO] ................. 09-02B BODY PANELS ............• 09-10
SYMPTOM DOORS AND LlFTGATE ..... 09-11
TROUBLESHOOTING GLASSIWINDOWS/
[POWER WINDOW SYSTEMS MIRRORS ............... 09-12
(WITH AUTO-OPEN/CLOSE SEATS .................... 09-13
FUNCTION FOR SECURITY AND LOCKS ..... 09-14
DRIVER-SIDE)] ........... 09-03A EXTERIOR TRIM ........... 09-16
SYMPTOM INTERIOR TRIM ............ 09-17
TROUBLESHOOTING LIGHTING SYSTEMS ........ 09-18
[KEYLESS ENTRY WIPERIWASHER SYSTEM ... 09-19
SYSTEM] . . . . . . . . . . . . . . . . 09-03B ENTERTAINMENT .......... 09-20
SYMPTOM POWER SYSTEMS .......... 09-21
TROUBLESHOOTING INSTRUMENTATION/DRIVER
[IMMOBILIZER SYSTEM] ... 09-03C INFO............•........ 09-22
TECHNICAL DATA .......... 09-50
SERVICE TOOLS ........... 09-60
09-02A ON-BOARD DIAGNOSTIC [IMMOBILIZER SYSTEM]

FOREWORD DTC 03 ..........................• 09-02A-3
[IMMOBILIZER SYSTEM] ........... 09-02A-1 DTC 11 ........................... 09-02A-4
DTCTABLE DTC 21 ........................... 09-02A-4
[IMMOBILIZER SYSTEM] ........... 09-02A-2 DTC 24 ........................... 09-02A-5
DTC 01 . . . . . . . . . . . . . . . . . . . . . . . . . . . 09-02A-2 DTC 30 ........................... 09-02A-5
DTC 02 ........................... 09-02A-3
FOREWORD [IMMOBILIZER SYSTEM]

dcf09026700Ow01
Caution
• When the engine does not start or stalls and the following DTCs are not indicated, go to engine
symptom troubleshooting.
Note
• When the immobilizer system is defective, the engine cannot be started .
. • If engine condition is normal but light stays on, inspect for short circuit between security light and
immobilizer unit connector terminal M. Repair or replace the wiring harness if necessary.
• The DDS1 is installed to the FIP with set bolts and cannot be removed. if there is a possibility that the
DDS1 is faulty, be sure to ask your distributor to repair it.
1. Turn the ignition switch to ON position.

2. Verify the security light condition and read the DTC if indicated.
3. If the DTC is indicated, go to troubleshooting referring to the DTC table.
09-02A-1
ON-BOARD DIAGNOSTIC [IMMOBILIZER SYSTEM]
DTC TABLE [IMMOBILIZER SYSTEM]
DTC Output pattern Description Page
01
] r ID number unregistered in immobilizer unit is (See 09-02A-3 DTC
input after engine switch is turned to ON
position or cranking engine.
01 [IMMOBILIZER
SYSTEM])
r
(See 09-02A-3 DTC
JUl
ID number format error (voltage range,
02 02[IMMOBILIZER
frequency)
SYSTEM])
ID number is not input into immobilizer unit (See 09-02A-4 DTC
03 after engine switch is turned to ON position 03[IMMOBILIZER
or cranking engine. SYSTEM])
(See 09-02A-5 DTC
Coil or wiring harness between immobilizer
11 11 [IMMOBILIZER
unit and coil is open circuit.
SYSTEM])
(See 09-02A-5 DTC
Code word/lD number stored in immobilizer
21 21 [IMMOBILIZER
unit EEPROM cannot be read.
SYSTEM])
(See 09-02A-6 DTC
Open or short circuit in wiring harness
24 24[IMMOBILIZER
between immobilizer unit and DDS1.
SYSTEM])
IG circuit of immobilizer unit is open circuit or
25
IG circuit of DDS1 is for short to B+ circuit.
(See 09-02A-8 DTC
DDS1 is defective. (Malfunction of
30 30[IMMOBILIZER
communication line inside DDS1)
SYSTEM])
Immobilizer unit or DDS1 is defective. (Code
41 words of immobilizer unit and DDS1 do not
match)
DDS1 is defective. (Communication error

42
between immobilizer unit and DDS1)
DDS1 is defective. (Malfunction of DDS1,
44 except for malfunctions related to DTC 30,
41, or 42
Note
• If DTC 25 and the other DTC are indicated, go to DTC 25 first and then go to the other DTC.
Note
• Perform the following if the security light stays on:
If engine stalls, go to symptom troubleshooting "NO.4 ENGINE STALLS-AFTER START/AT IDLE".
If engine will not start, go to symptom troubleshooting "NO.5 CRANKS NORMALLY BUT WILL NOT
START:' (See 01-03A-13 NO.5 CRANKS NORMALLY BUT WILL NOT START [WL-3])
If engine condition is normal but light stays on, inspect for continuity between the following wiring
harness and body ground: security light and immobilizer unit connector terminal M. Repair or replace
the wiring harness.
DTC01
dcf09026700Ow03
ID number unregistered in immobilizer unit is input after engine switch is turned to ON position or
DTC 01
engine cranking.
POSSIBLE
CAUSE • ID number is unregistered in immobilizer unit.
Go to ID number input procedure.
- - I -- (See 09-14-24 Key Replacement or Addition)
09-02A-2
DTC02
dcf090267000w04
OTC02 10 number format error (voltage range, frequency)

POSSIBLE
• Defective transponder in the key
CAUSE
Dispose of defective key.
- - - Duplicate key if necessary.
(See 09-14-24 Key Replacement or Addition)
DTC03
dcf09026700OwOS
10 number is not input into immobilizer unit after engine switch is turned to ON position or cranking
OTC03
engine.
• No transponder in the key
POSSIBLE • Defective transponder in the key (lD number is not output.)
CAUSE • Defective coil at steering lock
• Defective wiring harness between coil and immobilizer unit
COIL HARNESS SIDE

CONNECTOR
~
I, c I B
I A ]
I~~ I
1 • Does security light indicate DTC 11? Yes Go to DTC 11.
No Go to next step.
2 • Does security light indicate DTC 30? Yes Go to DTC 30.
No Go to next step.
3 INSPECT FOR OTHER PROPER KEYS Yes Dispose of defective key.
• Does engine start with other proper keys? Duplicate key if necessary.
(See 09-14-24 Key Replacement or Addition .)
No Go to next step.
4 INSPECT COIL CIRCUIT FOR SHORT TO Yes Repair the wiring harness connected to terminals A and/or
GNO OR COIL CIRCUIT FOR CONTINUITY C.
• Disconnect the coil connector. No Troubleshooting is completed.
• Inspect for short circuits between coil
connector terminals A and C and ground,
and also between coil connector terminals A
and C.
• Is there a short?
09-02A-3
DTC 11
dcf090267000w06
DTC 11 Coil or wiring harness between immobilizer unit and coil is open circuit.
• Open circuit in coil
POSSIBLE • Poor connection of coil connector
CAUSE • Poor connection of immobilizer unit
• Defective wiring harness between immobilizer unit and coil
COIL HARNESS SIDE IMMOBILIZER UNIT
CONNECTOR HARNESS SIDE CONNECTOR
[g]
I, C
I B I A ]
~ ~ ~3tf~ ~ I ~ I : I
I I
I~~ I IGt~ I
1 INSPECT CONNECTOR CONNECTION Yes Go to next step.
• Is connector of coil or immobilizer unit No Connect connector securely.
connected securely?
2 INSPECT COIL CIRCUIT FOR CONTINUITY Yes Go to next step.
• Is there continuity between coil terminals A No Replace coil.
and C?
3 INSPECT COIL CIRCUIT FOR CONTINUITY Yes Replace immobilizer unit and reprogram immobilizer
• Disconnect coil connector and immobilizer system.
unit connector. (See 09-14-28 Immobilizer Unit Replacement)
• Inspect if either of the following wiring No Repair wiring harness between coil and immobilizer unit.
harnesses has continuity.
- Immobilizer unit 0 to coil C, and
immobilizer unit F to coil A
- Immobilizer unit 0 to coil A, and
immobilizer unit F to coil C
Note
• Vehicle harness which is connected to
immobilizer unit terminals 0 and F, uses a
twisted pair wire. Because twisted pair
wire does not have polarity, immobilizer
unit connector terminal 0 may be
connected to coil connector terminal A or
C. Likewise, immobilizer unit connector
terminal F may be connected to coil
connector terminal A or C.
DTC21
dcf090267000w07
DTC21 Code word/lD number stored in immobilizer unit EEPROM cannot be read.
POSSIBLE
CAUSE • Defective immobilizer unit
- INSPECT IMMOBILIZER UNIT Yes Replace immobilizer unit and reprogram immobilizer
• Turn engine switch from LOCK position to system.
START position for 2 seconds. (See 09-14-28 Immobilizer Unit Replacement)
• Does security light indicate DTC 21 again? No Immobilizer system is o!{ay.
09-02A-4
DTC24
DTC24 Open or short circuit in wiring harness between immobilizer unit and DDS1
• Defective immobilizer unit
POSSIBLE • Defective DDS1
CAUSE • Poor connection of connector
• Defective wiring harness
IMMOBILIZER UNIT HARNESS
SIDE CONNECTOR
I~ I: ~1R~ ~ I~ I~ I
I~~I
1 INSPECT CONNECTOR CONNECTION Yes Go to next step.
• Are both immobilizer unit and FIP connectors No Connect connectors properly.
connected properly?
2 INSPECT COMMUNICATION CIRCUIT FOR Yes Go to Step 5.
CONTINUITY No Go to next step.
• Disconnect FIP connector.
• Measure voltage at FIP connector terminal
H.
• Is voltage more than 10 V?
3 INSPECT COMMUNICATION CIRCUIT FOR Yes Go to next step.
CONTINUITY No Repair wiring harness between DDS1 and immobilizer unit.
• Disconnect immobilizer unit and FIP
connectors.
• Is there continuity between immobilizer unit
connector terminal A and FIP connector
terminal H?
4 INSPECT IMMOBILIZER UNIT FOR SHORT Yes Repair for short circuit in wiring harness between DDS1 and
TOGND immobilizer unit.
• Is there continuity between immobilizer unit No Go to next step.
connector terminal A and ground?
5 INSPECT POWER CIRCUIT FOR OPEN Yes Go to next step.
CIRCUIT TO DDS1 No Repair wiring harness between ENGINE 15 A fuse and
• Turn engine switch to ON position. DDS1.
• Measure voltage at FIP connector terminal
G.
• Is voltage more than 10 V?
6 INSPECT DDS1 FOR SHORT TO GND Yes Go to next step.
• Turn engine switch to LOCK position. No Repair wiring harness between DDS1 and ground.
• Disconnect FIP connector.
• Is there continuity between FIP connector
terminal F and ground?
7 INSPECT INNER CIRCUIT OF IMMOBILIZER Yes Immobilizer unit was defective.
UNIT No Replace DDS1 and reprogram immobilizer system.
II
• Replace immobilizer unit and reprogram (See 09-14-5 IMMOBILIZER SYSTEM REPROGRAM
immobilizer system. PROCEDURE.)
(See 09-14-5 IMMOBILIZER SYSTEM
REPROGRAM PROCEDURE.)
• Dose engine start?
09-02A-5
DTC 30[IMMOBILIZER SYSTEM]
id0902e4904800
DTC30 DDS1 is defective (Malfunction of communication line inside DDS1)

POSSIBLE
CAUSE • Defective DDS 1
- - - Replace DDS1 and reprogram immobilizer system.
(See 09-14-5 IMMOBILIZER SYSTEM REPROGRAM
PROCEDURE.)
09-02A-6
ON-BOARD DIAGNOSTIC [AUDIO]
09-02B ON-BOARD DIAGNOSTIC [AUDIO]

STARTING PROCEDURE FOR SUPPLIER IDENTIFICATION
ON-BOARD DIAGNOSTIC TEST PROCEDURE .••.•.•••........•... 09-02B-1
MODE •.•....•.•..........•..••. 09-02B-1 MEMORY CLEARING PROCEDURE .•.. 09-02 B-2
DTC TABLE [AUDIO SYSTEM] ......•. 09-02B-2
DIAGNOSTIC ASSIST FUNCTION .•... 09-02B-4
STARTING PROCEDURE FOR ON-BOARD DIAGNOSTIC TEST MODE

dcf09026690Ow01
Note
• All OTCs displayed in the on-board diagnostic test mode should be entered in the Audio Repair Order
Form.
1. Turn the engine switch to the ACC or ON position.

2. Turn the POWER button off.
3. While pressing the POWER button,
simultaneously press the FM 1 button and the
MEOlA button for 2 s or more.
1 FM 1 button
2 MEDIA button
3 SEEK switch
4 POWER button
Note
• If several OTCs are in the memory, they can
be displayed using the SEEK switch (up or 4
down). DCF902ZWBS01
4. To stop the on-board diagnostic test mode, turn the engine switch off.
SUPPLIER IDENTIFICATION PROCEDURE

dcf09026690Ow02
Note
• The supplier can vary with the module. When asking the supplier (service center) for repair or
replacement, identify the supplier and fill in the Audio Repair Order Form with the following procedures.
Identification Using the Label or Inscribed Lettering

1. Remove the audio unit.
2. Verify the supplier by referring to the label attached to each unit.
Jdentification Using the On-board Diagnostic Test Mode.

1. Start the on-board diagnostic test mode.
2. Identify the device and supplier codes by referring
to the information display.
SUPPLIER CODE
,....-...
...., •..... •. ....
Note
• If no OTC is stored, no codes will be
displayed. ,
I.
,
• • • • II
•• •
II
••• ,.1.I ••
• I I . • •• •
1111
• II
•••
•• I.
• • ••
Supplier code Supplier name

•
.:.
II I
'.11' II' II II...
• .• ...• 11 ••
• •
•.•
• •• I
1 SANYO Automedia •
PART NUMBER
2 Panasonic
3 Clarion
CHU0902WM02
4 Pioneer
Part
Part name
number
03 CD player
05 CD changer (external)
09-028-1
Part
Part name
number
06 CD changer (upper module)
O? MD player (lower module)
09 Base unit
10 MP3 applicable CD player system
21 Center panel
22 MP3 applicable CD changer (upper module)
MEMORY CLEARING PROCEDURE

dcf090266900w03
1. Start the on-board diagnostic test mode.

2. While pressing the POWER button,
simultaneously press the AUDIO CaNT button for
2 s or more.
IAUDIO CO NT button
2 POWER button
Caution
• Before clearing the memory, be sure to
enter all of the DTCs displayed in the on-
board diagnostic test mode in the Audio
Repair Order Form.
DCF902ZWBS02
3. To stop the on-board diagnostic test mode, turn
the engine switch off.
DTC TABLE [AUDIO SYSTEM]

dcf090266900w04
Screen display
DTC Detection condition Possible cause/inspection
(When starting on-board
diagnostic test function)
CD player cannot implement CD player malfunction
03: Er01
insert and eject commands.
03: Er02 Cannot change tracks. CD player malfunction
03: ErO?
CD reading error. • Defective CD (scratches or dirt)
• CD player malfunction
CD player does not operate. • Malfunction of connectors between base unit and CD
03: Er10 player
• CD player malfunction
CD changer (external) cannot • Defective CD (curved, broken or foreign material stucki
05: Er01 implement insert, eject, and disc attached, etc.)
change commands. • CD changer (external) malfunction
CD reading error. • Defective CD (curved, broken or foreign material stucki
05: ErO? attached, etc.)
• CD changer (external) malfunction
CD changer (external) does not • Defective CD (curved, broken or foreign material stucki
05: Er10 operate. attached, etc.)
• CD changer (external) malfunction
CD changer cannot implement • Defective CD (curved, broken or foreign material stucki
06: Er01 insert, eject, and disc change attached, etc.)
commands. • CD changer malfunction
Cannot change tracks. • Defective CD (curved, broken or foreign material stucki
06: Er02 attached, etc.)
• CD changer malfunction
06: ErO? attached, etc.)
CD changer does not operate. • Malfunction of connectors between base unit and CD
06: Er10 changer
09-028-2
Screen display
DTe Detection condition Possible cause/inspection
(When starting on-board
diagnostic test function)
MD player cannot implement MD player malfunction
07: Er01
insert and eject commands.
07: Er02 Cannot change tracks. MD player malfunction
07: Er07 MD reading error. Defective MD
07: Er08 Blank unrecorded MD is inserted. Defective MD
MD player does not operate. • Malfunction of connectors between base unit and MD
07: Er10 player
• MD player malfunction
09: Er20 Audio system does not operate. Voltage at base unit is low.
Broken sound/No sound Inspect the audio system operation according to vehicle
09: Er21
condition.
09: Er22 No radio reception Inspect the radio operation according to vehicle condition.
MP3 applicable CD player cannot MP3 applicable CD player malfunction
10: Er01 implement insert and eject
commands.
10: Er02 Cannot change tracks. MP3 applicable CD player malfunction
10: Er07 MP3 CD reading error. Incorrect format CD
10: Er09
MP3 CD data is unreadable. • CD data error
• No playback data on the CD
MP3 applicable CD player does • Malfunction of connectors between base unit and MP3
10: Er10 not operate. applicable CD player
• MP3 applicable CD player malfunction
21: Er17 Incorrect combination (base unit Install the correct base unit or the center panel.
21: Er18 and center panel)
Communication error between Malfunction of connectors between base unit and center
21: Er19
base unit and center panel panel
MP3 applicable CD changer • Defective CD (curved, broken or foreign material stucki
22: Er01 cannot implement insert, eject, attached, etc.)
and disc change commands. • MP3 applicable CD changer malfunction
Cannot change tracks. • Defective CD (curved, broken or foreign material stucki
• MP3 applicable CD changer malfunction
22: Er09
MP3 CD data is unreadable. • CD data error
• No playback data on the CD
MP3 applicable CD changer does • Malfunction of connectors between base unit and MP3
22: Er10 not operate. applicable CD changer
no Err No DTCs stored No DTCs stored
09-028-3
DIAGNOSTIC ASSIST FUNCTION
dcf090266900w05
Structural View
Buttons
® @ II ®
17
DCF902ZWBS03
1 CLOCK button 10 Preset button 4

4 AM button 13 DISP/AUTO-M button
5 CD button 14 SEEKlAPCITRACK switch
6 MEDIA button 15 Traffic information button
7 Preset button 1 16 AUDIO CONTITUNEITEXT button
8 Preset button 2 17 POWERNOLUME button
9 Preset button 3
Information Display Inspection

1. With the audio power on, press the POWER button and simultaneously press the SEEK switch (up or down) for
approx.1s.
2. Inspect according to the following table:
INSPECTION DISPLAY ACTION
Start the information display The characters displayed The information display is
inspection mode. on the information display normal.
are not truncated or faint.
IBB:BBlfgml1ll'iriiii'it Except above Replace the base unit.
(See 09-20-4 AUDIO UNIT
DISASSEMBLYI
ASSEMBLY [TYPE A].)
3. Turn the audio off or the ignition switch to the LOCK position to stop the diagnostic assist function.
09-028-4
Speaker Inspection
1. With the audio power on, press the POWER button and simultaneously press the AUTO-M button for approx.
1s.
• Start the speaker inspection
Yes
Speakers, and wiring harness between
mode. the base unit and speakers are normal.
• Does each speaker output
• Inspect the following parts .
sound in the following order? - Malfunctioning speaker
1. Front speaker and tweeter - Wiring harness between base unit
(LH) - and malfunctioning speaker
2. Front speaker and tweeter No
(RH)
3. Rear speaker (RH)*1
4. Rear speaker (LH) *1
*1 : Mayor may not be equipped, depending on the vehicle.
Radio Reception Condition Inspection

1. With the audio power on and at radio mode, press the POWER button and simultaneously press the Preset 2
button for approx. 1 s.
Caution
• Even if the system is normal, radio reception may be difficult depending on where the system is
inspected (indoors/outdoors, or conditions at the location). Before inspecting the system, verify
that radio reception is adequate.
• When inspecting, select a frequency band (radio station) with the best reception.

Start the radio reception Antenna, antenna feeder and base unit are normal
condition inspection mode. NORMAL CONDITION
S-METER 5
I
S~METER 9
Change the frequency (radio station) and inspect again.
S-METER 3
I
S-METER 4
Inspect the antenna and antenna feeder.
MALFUNCTION PRESENT • If either the antenna or the antenna feeder is not
S-METER 0 normal, replace the malfunctioning part.

• If the antenna and antenna feeder are normal,
replace the base unit.
I
S-METER 2
09-028-5
Antenna control condition inspection
1. With the audio power on and at radio mode, press the POWER button and simultaneously press the FM 2
button for approx. 1 s.
2. Inspect the antenna control conditon according to the following table:
Inspection Display Action
Start antenna control condition Sound quality is good. System is okay.
inspection mode.
I=INT-ON Sound quality is poor. Inspect the roof antenna.
Replace base unit.
I=INT-OFF
09-028-6
SYMPTOM TROUBLESHOOTING [POWER WINDOW SYSTEMS (WITH AUTO-
OPEN/CLOSE FUNCTION FOR DRIVER-SIDE)]
09-03A SYMPTOM TROUBLESHOOTING [POWER

WINDOW SYSTEMS (WITH AUTO-OPEN/CLOSE FUNCTION
FOR DRIVER-SIDE)]
POWER WINDOW SYSTEM NO.3 POWER WINDOWS OTHER
WIRING DIAGRAM ................ 09-03A-1 THAN DRIVER'S SIDE DO NOT
FOREWORD ...................... 09-03A-2 OPERATE BY SUBSWITCH ......... 09-03A-9
POWER WINDOW SYSTEM NO.4 POWER WINDOWS OTHER
TROUBLESHOOTING THAN DRIVER'S SIDE DO NOT
QUESTIONNAIRE . ................ 09-03A-3 OPERATE BY MAIN SWITCH ....... . 09-03A-9
SYMPTOM TROUBLESHOOTING NO.5 POWER WINDOWS OTHER
CHART . ......................... 09-03A-4 THAN DRIVER'S SIDE DO NOT
BASIC POWER WINDOW SYSTEM OPERATE BY MAIN SWITCH AND
INSPECTION . .................... 09-03A-4 SUBSWITCH . .................... . 09-03A-9
NO.1 THE AUTO OPEN/CLOSE NO.6 THE DRIVER'S SIDE POWER
FUNCTION ON THE DRIVER'S SIDE WINDOW AUTOMATICALLY OPENS
,POWER WINDOW IS INOPERATIVE IN THE CLOSING OPERATION . ..... . 09-03A-11
[WITH AUTOMATIC DOOR GLASS NO.7 ABNORMAL NOISE DURING
RETURN FUNCTION] .............. 09-03A-7 THE POWER WINDOW
NO.2 THE DRIVER'S SIDE POWER OPERATION . .................... . 09-03A-13
WINDOW INOPERATIVE ........... 09-03A-7
POWER WINDOW SYSTEM WIRING DIAGRAM

dcf09035800Ow13
MANUAL MANUAL AUTO

CLOSE OPEN POWER WINDOW MAIN SWITCH
IG1
B+
POWER-CUT
SWITCH
CLOSE/, CLOSE/ CLOSE/

OPEN OPEN OPEN
OPEN
RELAY
CLOSE
DOOR SWITCH RELAY L....+---*--+--l
(DRIVER'S SIDE)
HALL EFFECT SWITCH NO.1
1--.-----!:~--4~ I I! - POWER
I--.----~,-i
1--._ _ _ _ _' ---.
I M
:
:
I
lI
.. ..
I
:l
I I
I " "
I
l
I
..
I WINDOW
SUBSWITCH
1--._ _ _ _ _.;..:--I : M y: M REAR POWER

DOOR SWITCH
HALL EFFECT SWITCH NO.2, : : REAR POWER WINDOW 'WINDOW
(REAR LEFT SIDE)
FRONT POWEFiwiNOOW -------- WINDOW
MOTOR (DRIVER'S SIDE)
FRONT POWER
MOTOR
:
~
MOTOR (RIGHT SIDE) : MOTOR
_____________________________, (LEFT SIDE)
(PASSENGER'S SIDE) WITH REAR POWER WINDOW SYSTEM
POWER POWER
WINDOW WINDOW
( SUBSWITCH SUBSWITCH
DBR912ZT2003
09-03A-'1
FOREWORD
dcf09035800Ow14
Troubleshooting Procedure
Confirm to the customer using the "Power Window System

Troubleshooting Questionnaire"
NO
Confirm the symptom on-vehicle
NO Carry-out the basic

Is there same symptom in the
Symptom Troubleshooting inspection
Chart?
YES
Follow the appropriate

diagnostic procedure
Repair the problem
Complete
DCF903ZWB101
Caution
• The power window system initialization is required after performing below operations. Because of
both the automatic operation and tow-step down return function are reset by the operations.
- Disconnect the negative battery cable from the battery terminal.
- Disconnect the power window main switch connector.
- Remove the fuse for the power window system.
• Power window system initialization procedures:
2. Fully open the driver side front door glass by operating the driver side front window switch.
3. Fully close the driver side front door glass using the driver side front window switch and hold
the switch for two seconds.
• Slightly shake the wiring harness and connectors while performing the inspection to discover
whether poor contact pOints are the cause of any intermittent malfunctions.
09-03A-2
POWER WINDOW SYSTEM TROUBLESHOOTING QUESTIONNAIRE
dcf090358000w15
Date:
When the malfunction is occurred.

I
Outside
Weather condition o Fair weather DCloudy 0 Rain 0 Snow 0 Other ( )
I temperature I Approx. F
Driving condition o Driving OStop (Engine is : o Running 0 Stoped)
Duplicate symptom OYES ONO

I Frequency
I o Always 0 Sometimes ( times/month)
Road conditions o City OOuter city 0

Freeway OOther ( ) /0 Pavage 0 Dirt track
,
*Follow the appropriate diagnostic procedures shown below or perform the basic flow of Troublesho.
o (No.1) The auto open/close function on the driver's side power window inoperative.
o (No.2) The driver's side power window inoperative.
o (No.3) Power windows other than driver's side do not operate by sub-switch.
o (No.4) Power windows other than driver's side do not operate by main swhch.
o (No.5) Power windows other than driver's side do not operate by main switch and sub-switch.
o (No.6) The driver's side power window automatically opens in the closing operation.
Please clarify the position that the driver side front door glass opens automatically. 0 Completely closed position
o Approx. ( )mm lower than completely position OApprox. ( )mm upper than the completely position.
o (No.7) Abnormal noise during the power window operation

o Other (Describe the symptom below if there is no symptom in the above list.)
# l~
Please describe any condition when the malfunction occurs.

iI(! 1111
(Example) : Operate outside door mirror operation, etc
Please describe any condition that the system returns to normal operation after malfunctioning.
(Example) : Turn the ignition switch to ON position after inserting the ignition key into the key cylinder, etc
Installed Accessory Part availability

(Example) : Side visor, Immobilizer, Rader, ect(regardless genuine parts or sfter-market parts)
DCF903ZWB102
09-03A-3
SYMPTOM TROUBLESHOOTING CHART
dcf090358000w16
No. Malfunction symptom

1 09-03A-7 NO.1 THE AUTO OPEN/CLOSE FUNCTION ON THE DRIVER'S SIDE POWER WINDOW IS
INOPERATIVE [WITH AUTOMATIC DOOR GLASS RETURN FUNCTION]
2 09-03A-7 NO.2 THE DRIVER'S SIDE POWER WINDOW INOPERATIVE
3 09-03A-9 NO.3 POWER WINDOWS OTHER THAN DRIVER'S SIDE DO NOT OPERATE BY SUBSWITCH
4 09-03A-9 NO.4 POWER WINDOWS OTHER THAN DRIVER'S SIDE DO NOT OPERATE BY MAIN SWITCH
5 09-03A-9 NO.5 POWER WINDOWS OTHER THAN DRIVER'S SIDE DO NOT OPERATE BY MAIN SWITCH AND
SUBSWITCH.
6 09-03A-11 NO.6 THE DRIVER'S SIDE POWER WINDOW AUTOMATICALLY OPENS IN THE CLOSING
OPERATION
7 09-03A-13 NO.7 ABNORMAL NOISE DURING THE POWER WINDOW OPERATION.
BASIC POWER WINDOW SYSTEM INSPECTION

dcf090358000w17
Manual Mode Function Inspection

1 • Turn the ignition switch to the ON position. Yes Go to the next step.
• Operate the power window using the manual No • Inspect the power window main switch and the
open/close function on the power window main wiring harness.
switch. • Repair or replace malfunctioning part.
• Does the power window operate properly?
2 • Set the power cut switch to the UNLOCK Yes Go to the next step.
position. No • Inspect for the power window subswitch and the
• Operate the power window using the power wiring harness.
window subswitch.
• Repair or replace malfunctioning parts.
3 • Set the power cut switch to the LOCK position. Yes • Inspect the power cut switch and the wiring harness.
• Operate ali power windows other than the driver • Replace the power window main switch.
side. No • Manual mode function is normal.
• Does the power window operate?
• Perform the automatic mode function inspection.
Automatic Mode function Inspection
Note
• Automatic mode function is equipped with automatic door glass return function adapted model.

• Operate the power window using the auto open / No If the power window automatically opens in
close function on the power window main switch.
the closing operation:
• Go to 09-03A-11 NO.6 THE DRIVER'S SIDE
POWER WINDOW AUTOMATICALLY OPENS IN
THE CLOSING OPERATION
Others:
• Go to 09-03A-7 NO.1 THE AUTO OPEN/CLOSE
FUNCTION ON THE DRIVER'S SIDE POWER
WINDOW IS INOPERATIVE [WITH AUTOMATIC
DOOR GLASS RETURN FUNCTION]
2 • Operate the power window main switch to the Yes Go to the next step.
close position while the power window is in
opening operation.
No • Replace the power window main switch. (power
window control unit is malfunctioning.)
• Is the power window operation stopped?
3 • Operate the power window main switch to open Yes • Automatic mode function is normal.
position while the power window is in closing • Perform the IG-OFF timer function inspection.
operation. No • Replace the power window main switch. (power
• Is the power window operation stopped? window control unit is malfunctioning.)
09-03A-4
IG-OFF Timer Function Inspection
Note
• IG-OFF timer function is equipped with automatic door glass return function adapted model.

1 • Close all doors. Yes • Go to the next step.
• Turn the ignition switch to the ON position .. No • If it does not move up and down upon reinspection,
• In automatic mode, push down the power inspect the following:
window main switch for the driver-side front door - Wiring harness for the door open/close signal
glass. The door glass should move down within system.
approx. 43s after ignition switch off. - Latch switch.
• In manual mode (finger continuously depressing
• Repair or replace the malfunctioning part, and
the power window main switch), the door glass reinspect.
should move down within approx. 43s after - If operation is not normal, replace the power
ignition switch off. window main switch, and then go to the next
• Does the driver-side front door glass move step.
down?
2 • Turn the ignition switch to the ON position Yes • If operation is not normal, replace the power window
• In automatic mode, pull up the power window main switch, then go to the next step.
main switch for the driver-side front door glass.
The door glass does not move up within approx.
No • Go to the next step.
43s after ignition switch off.

• Verify that driver-side front door glass does not
operate
• Does the driver-side front door glass move up?
3 • Open any doors. Yes • Inspect the door switch and related wiring harness.
• Turn the ignition switch to the ON position. • If above parts are normal, replace the power
• Push/pull the power window main switch for the window main switch, then go to the next step.
door glass within approx. 43s after ignition • If the above parts have any malfunction, repair or
switch off. replace the malfunction part, then go to the next
• Verify that the door glass does not move up or step.
down. No • Go to the next step.
• Does the door glass move up or down?
4 • Close all doors. Yes • If operation is not normal, replace the power window
• Turn the ignition switch to the ON position. main switch, then go to the automatic door glass
• Push/pull the power window main switch for door return function inspection.
glass after approx. 60 s after ignition switch off. No • The IG OFF timer function is normal.
• Verify that the door glass does not move up or
• Go to the automatic door glass return function
down. inspection.
• Does the door glass move up or down?
09-03A-5
Auto Reverse Pinch Protection Function Inspection
1 • Turn the ignition switch to the ON position. Yes • Automatic door glass return function is normal.
• Fully open the driver's side power window. • Perform the two-step down function inspection.
• Set the hammer (thickness: 10 mm or more) as No Go to the next step.
shown below. Then, close the power window
using auto close function.
• Inspect that the power window opens by 200 mm
after contacting the hammer and stops the
operation.
• Does automatic door glass return function
operate properly?
2· • Does power window open before contacting the Yes • Go to 09-03A-11 NO.6 THE DRIVER'S SIDE
hammer? POWER WINDOW AUTOMATICALLY OPENS IN
THE CLOSING OPERATION
No • Initialize the power window main switch.
Note
• Before initializing the power window main switch,
cut off the power supply to the power window
main switch for 60 seconds. Then, reconnect or
install it again after 60 seconds:
<Power supply cut-off method>
- Disconnect the negative battery cable from the
battery terminal.
- Disconnect the power window main switch
connector.
- Remove the fuse for the power window
system.
DDA903AW4S04
09-03A-6
NO.1 THE AUTO OPEN/CLOSE FUNCTION ON THE DRIVER'S SIDE POWER WINDOW IS INOPERATIVE
[WITH AUTOMATIC DOOR GLASS RETURN FUNCTION]
dcf090358000w18
1 The auto open/close function on the driver's side power window is inoperative
• No power supply to power window main switch
POSSIBLE • Power window main switch malfunction (power window control unit malfunction, auto switch
malfunction)
CAUSE
• Power window motor malfunction (Sensor inside motor malfunction)
• Wiring harness between power window motor (sensor) and power window main switch malfunction
1 • Turn the ignition switch to the ON position. Yes Replace the power window main switch.
• Inspect the manual mode function. No Go to the next step.
• Dose the manual mode function operate
properly?
2 • Does the sensor built inside the power Yes Go to the next step.
window motor send the pulse signals during No Replace the power window motor.
operating the power window motor?
• Is voltage between the terminals of power
window mortor connecter (4-pin) and ground
approx.6V?
- Terminal1A (sensor 1 signal).
- Terminal1C (sensor 2 signal).
3 • Does the power window main switch receive Yes Replace the power window main switch.
the pulse signals during operating the power No Inspect open or short circuit in the wiring harness between
window motor? power window motor (sensor) and power window main
• Is voltage between the terminals of power switch. Inspect the connection of the power window motor
window main switch connecter (4-pin) and and power window main switch connectors. (such as
ground approx.6V? damaged/pulled-out pins, corrosion).Repair or replace the
- Terminal2D (sensor 1 signal). suspect part if necessary.
- Terminal2B (sensor 2 signal).
NO.2 THE DRIVER'S SIDE POWER WINDOW INOPERATIVE

dcf090358000w19
2 The driver's side power window inoperative

• Power supply circuit or ground circuit malfunction
- Burnt fuse (B+)
- Open or short circuit in wiring harness between fuse (B+) and power window main switch
POSSIBLE
- Open or short circuit in wiring harness between power window main switch and power window motor
CAUSE
- Open circuit in wiring harness between power window main switch and ground
• Power window main switch malfunction (Internal circuit malfunction, relay malfunction)
• Power window motor malfunction (motor malfunction, window regulator guide malfunction)
• Turn the ignition switch to the ON position. Yes Go to Step 6.
• Does the LED on the power window main No Go to the next step.
switch illuminate?
2 • Operate all power windows other than Yes Go to the next step.
driver's side window using the power window No Inspect open or short circuit and connection in the following
main switch. wiring harnesses/connections
• Does the power window operate properly? Automatic door glass return function is equipped:
• P.WIND 30 A fuse-Power window main switch
connector terminal 1F
• Power window main switch connector terminal 1H-
body ground.
Automatic door glass return function is not
equipped:
( • P.WIND 30A fuse-Power window main switch terminal
F
• Power window main switch terminal H-ground.
Repair or replace the suspect part if necessary.
09-03A-7

3 • Is the PWIND 30 A fuse normal? Yes Automatic door glass return function is equipped:
Go to Step 5.
Automatic door glass return function is not equipped:
• Replace the power window main switch.
(See 09-12-8 POWER WINDOW MAIN SWITCH
No Inspect the followings:
• Short circuit in B+ power supply wiring harness
• Short circuit in power window motor
Repair or replace the suspect part if necessary. Replace with
the appropriate standard fuse. Then, go to the next step.
4 • Initialize the power window system. Yes Troubleshooting is completed.
• Operate the power window systemoperation. No Re-confirm the symptom and go to Step 1 in this procedure.
• Does power window operate properly?
5 • Measure the voltage at power window main Yes Replace the power window main switch.
switch (battery power supply terminal 11) . No Inspect open or short circuit in the power window main
• Is the voltage B+? switch wiring harness (battery power supply).
Inspect the connection of the power window main switch
connector. (such as damaged/pulled-out pins, corrosion).
6 • Measure the voltage at the power window Yes Go to the next step.
main switch (power window motor output No Replace the power window main switch.
terminal) during operating the power window
using the power window main switch.
(Open: terminal 1 K*11/(2
Close: terminal 1M*11 /K*2 )
7 • Measure the voltage at power window motor Yes Go to the next step.
(2-pin)(battery power supply terminal) during No Inspect open or short circuit in the wiring harness between
operating the power window using the power power window main switch and power window motor.
window main switch. Inspect the connection of the power window main switch
• Is the voltage B+? and power window motor connectors. (such as damaged/
(Open: terminal 1 8/ close: terminal1A) pulled-out pins, corrosion).
8 • Operate the driver's side power window Yes Go to the next step.
using the power window main switch. No Replace the power window motor.
• Does power window motor operate (rotate)?
Note
• The power window motor does not
operate during the power window motor
internal temperature is too high. Leave the
motor for 3 minutes and inspect the power
window motor operation again after
cooling down the motor temperature.
9 • Remove the door glass from the carrier plate. Yes Replace the regulator guide.
• Make sure that the door glass moving No Inspect for bent regulator guide or other possible facts. If
smoothly by hand. there is normal, replace the door glass run-channel.
• Is the door glass move smoothly?
*1 : With automatic door glass return function

*2
: Without automatic dooe glass return function
09-03A-8
SYMPTOM TROUBLESHOOTING [POWER WINDOW SYSTEMS (WITH AUTO·
NO.3 POWER WINDOWS OTHER THAN DRIVER'S SIDE DO NOT OPERATE BY SUBSWITCH
dcf090358000w20
3 Power windows other than driver's side do not operate by subswitch

POSSIBLE • Open or short circuit in power window subswitch wiring harness (battery power supply circuit)
CAUSE • Power window subswitch malfunction
1 • Turn the ignition switch to ON position. Yes Replace the power window subswitch.
• Set power cut-switch on power window main No Inspect open or short circuit in the wiring harness between
switch to UNLOCK position. power window main switch and power window
• Measure the voltage at power window sub- subswitch.lnspect the connection of the power window
switch (terminal C). subswitch connector. (such as damaged/pulled-out pins,
• Is the voltage B+? corrosion).Repair or replace the suspect part if necessary.
NO.4 POWER WINDOWS OTHER THAN DRIVER'S SIDE DO NOT OPERATE BY MAIN SWITCH
dcf090358000w21
4 power windows other than driver's side do not operate by main switch
POSSIBLE • Open or short circuit in wiring harness between ignition switch (IG1) and power window main switch
(lG1)
CAUSE
• Power window main switch malfunction
Diagnostic procedures
1 • Turn the ignition switch to ON position. Yes Replace the power window main switch.
• Set power cut-switch on power window main No Inspect open or short circuit in the power window main
switch to UNLOCK position. switch wiring harness (battery power supply ).Inspect the
• Operate all power windows other than connection of the power window main switch connector.
driver's side using the power window main (such as damaged/pulled-out pins, corrosion). Repair or
switch. replace the suspect part if necessary.
• Does power window operate properly?
NO.5 POWER WINDOWS OTHER THAN DRIVER'S SIDE DO NOT OPERATE BY MAIN SWITCH AND
SUBSWITCH.
dcf090358000w22
5 All power windows are inoperative

• Power supply circuit or ground circuit malfunction
- Burnt fuse (IG1)
- Open or short circuit in wiring harness between ignition switch (IG1) and power window main switch
- Open or short circuit in wiring harness between power window main switch and power window
POSSIBLE subswitch
CAUSE - Open or short circuit in wiring harness between power window main switch and power window motor
- Open circuit in wiring harness between power window main switch and ground
• Power window main switch malfunction (power cut-off switch malfunction, switch malfunction)
• Power window subswitch malfunction
• Power window motor malfunction(motor malfunction, window regulator guide malfunction)
• Turn the ignition switch to ON position. Yes System is now normal. (power cut-off switch dose not set
• Set the power cut-off switch on power properly.)
window main switch to UNLOCK position. No Go to the next step.
• Inspect the power window system operation
again.
• Does the system operate properly?
2 • Operate all power windows other than Yes Go to Step 6.
driver's side window using power window No Go to the next step.
main switch.
• Does any power window operate?
09-03A-9
3 • Operate driver's side power window using Yes Go to the next step.
the power window main switch. No Inspect open circuit in the wiring harness between power
• Does power window operate? window main switch and body ground.
4 • Is the P.wIND 30 A fuse normal? Yes Automatic door glass return function is equipped:
Automatic door glass return function is not equipped:
Replace power window main switch.(See
09-12-8 POWER WINDOW MAIN SWITCH REMOVAL!
INSTALLATION)
No • Replace with the appropriate standard fuse.
- If the fuse is melted, inspect the wiring harness for
short to ground.Repair or replace the wiring harness,
then replace the fuse.
5 • Measure the voltage at power window main Yes Replace power window main switch.
switch (battery power supply terminal 11) No Inspect open or short circuit in the power window main
• Is the voltage B+? switch wiring harness (battery power supply).
connector. (such as damaged/pulled-out pins; corrosion).
6 • Identify the inoperative power window. Yes Go to the next step.
• Measure the voltage at suspect power No Go to Step 9.
window motor (battery power supply) during
operating the power window motor using the
suspect power window sub-switch.
(Open: terminal 8/ close: terminal A)
7 • Operate power window using the power Yes Go to the next step.
window sUb-switch. No Replace power window motor.
• Does power window motor operate (rotate)?
Note
• The power window motor does not
operate during the power window motor
internal temperature is too high. Leave the
motor for 3 minutes and inspect the power
window motor operation again after
cooling down the motor temperature.
8 • Remove the door glass from the carrier plate. Yes Replace regulator guide.
• Make sure that the door glass moving No Inspect for bent regulator guide or other possible facts. If
smoothly byhand. there is normal, replace the door glass run-channel.
• Is the door glass move smoothly?
9 • Measure the voltage at power window sub- Yes Inspect open or short circuit in the wiring harness between
switch (power window motor output) during power window sub-switch and power window motor.
operating the power window sub-switch. Inspect the connection of the power window subswitch and
• Is the voltage B+? power window motor connectors. (such as damaged/pulled-
(open:terminal F/close:terminal 8) out pins, corrosion).
10 • Disconnect power window sub-switch Yes Go to the next step.
connector. No Inspect open or short circuit in the power window sub-switch
• Inspect the continuity between power wiring harness.
window sub-switch terminal 8 and ground. Inspect the connection of the power window subswitch
• Is there a continuity? connector. (such as damaged/pulled-out pins, corrosion).
Repair or replace the suspect part if necessary
Then, go to STEP 12.
11 • Inspect the continuity between power Yes Replace power window subswitch.
window sub-switch terminal F and ground. No Inspect open or short circuit in the power window sub-switch
• Is there continuity? wiring harness.
Inspect the connection of the power window sub-switch
Repair or replace the suspect part if necessary
Then, go to STEP 12.
09-03A-10
• Do not operate the power window main No Replace the power window main switch .
switch during the following inspection.
• Inspect the continuity between power

window main switch terminals (1 A, 1B, 1J)*1/
(A, B, J) *2 and ground.
13 Note Yes Inspect open or short circuit in the wiring harness between
• Do not operate the power window main power window main switch and power window sub-switch.
switch during the following inspection. Inspect the connection of the power window main switch
and sub-switch connectors. (such as damaged/pulled-out
• Inspect the continuity between power pins, corrosion).
window main switch terminal (1 C, 10, 1L)*1 / Repair or replace the suspect part if necessary.
(C, 0, L)*2 and ground. No Replace power window main switch.
• Is there a continuity?
*1
: With automatic door glass return function
*2
: Without automatic door glass return function
NO.6 THE DRIVER'S SIDE POWER WINDOW AUTOMATICALLY OPENS IN THE CLOSING OPERATION
dcf09035800OW23
6 The driver's side power window automatically opens in the closing operation.
• Increase sliding resistance of door glass while raising the glass.
- Improper installation of side visor
- Regulator motor malfunction
- Pinch any foreign material between door glass and door glass run channel
- Inadequate installation of carrier plate and door glass
- Door glass run channel malfunction
- Door glass guide malfunction
POSSIBLE Note
CAUSE • When the switch detects to pinch something, auto reverse pinch protection function operates to open
the door glass automatically.
• If the sliding resistance of door glass is increased and door glass raising speed is slow down, the
auto reverse pinch protection function sometime operates.
• If the door glass raising speed is slow down, inspect the following parts:
- If door glass rotates forward slightly: inspect the vehicle front side of door glass guide and/or door
glass run channel.
- If door glass rotates backward slightly: inspect the vehicle rear side of door glass guide and/or
door glass run channel.
• Confirm the symptom. Yes System is normal.
• Does the symptom occur under the following (Explain to customer that this is normal operation on this
condition? system.)
- Bumping road. No Go to the next step.
- Opening/closing door.
2 • Inspect the side visor installation condition. Yes Go to the next step.
• Is the side visor normal? No Install the side visor properly, then go to the next step.
3 • Put any tape on the back side of the door Yes Put the mark the speed change position on either door shell
glass. or door glass run channel. Go to STEP 5.
• Run the engine at idle. No Go to the next step.
• Inspect the door glass operating speed.
• Is there any speed change? (e.g., slow
down)
4 • Inspect the door glass operating speed again Yes Replace the regulator motor. Then go to STEP 8.
• Is the speed change frequently (e.g., 5-6 =-0-'-to-S-=-t-e-p-8-.--=---------=------------1
f---,N""'0-I-G
times)?
09-03A-11

5 • Is there any foreign material between door Yes If there is any foreign material:
glass run channel and door glass? • Remove the foreign material.
• Is there any rough surface on the sliding If there is any rough surface on the sliding
surface?
surface:
• Replace the door glass run channel.
Confirm the symptom again. If there is a same symptom,
return to STEP 3.
6 • Inspect the installation condition of carrier Yes Go to the next step.
plate and door glass. No Install them securely. Confirm the symptom again.
• Are both parts installed securely? If there is a same symptom, return to STEP 3.
7 • Inspect the door glass run channel and door Yes Go to the next step.
glass guide. No Install door glass run channel and door glass guide properly.
• Are both parts normal? Confirm the symptom again.
If there is a same symptom, return to STEP 3.
8 • Inspect the door glass operating speed. Yes perform STEP 3 in this procedure again.
• Is there any speed change? No Troubleshooting is completed.
If door glass slips rearward slightly
If door glass slips forward slightly

Affix tape to rear edge
DCF903ZWB1S0
09-03A-12
NO.7 ABNORMAL NOISE DURING THE POWER WINDOW OPERATION.
dcf090358000w24
7 Abnormal noise during the power window operation.

• Loosen bolt for installing the door glass to the carrier plate .
• Deform resin part on the regulator.
- Wear mark on the resin part caused by cable.
POSSIBLE - Deform gear inside regulator motor.
CAUSE
Note
• Identify the noise generating place using the stethoscope or any equivalent.
Abnormal Occurrence
Possible route cause Noise generating place Action
noise timing
Clicking noise Beginning of Loosen bolt for installing the door Between carrier plate Re-tighten bolt.
door glass glass to carrier plate. and lower side of door
operation glass.
Groaning noise While operating Noise is created due to the wear Regulator guide. Replace regulator guide
door glass mark on the resin part of the
regulator guide caused by cable.
Note
• There is no groaning noise
on the vehicle equipped with
roller type regulator guide ..
Booming noise Deform gear inside regulator motor Gear inside regulator Replace the regulator
Chattering noise motor motor
POWER WINDOW MOTOR CARRIER PLATE
POWER WINDOW
REGULATOR
DCF912ZWB525
OS-03A-13
i.
SYMPTOM TROUBLESHOOTING [KEYLESS ENTRY SYSTEM]
09-03B SYMPTOM TROUBLESHOOTING [KEYLESS

ENTRY SYSTEM] .
KEYLESS ENTRY SYSTEM ON-BOARD DIAGNOSTIC
WIRING DIAGRAM ....•....•...•.. 09-03B-1 FUNCTION ....•..••..•....••..••• 09-03B-4
FOREWORD ........••..••........ 09-03B-1 TROUBLESHOOTING INDEX .•..•.•.. 09-03B-4
KEYLESS ENTRY SYSTEM NO.1 ON-BOARD DIAGNOSTIC
CHECK SHEET •••.•.••.......•... 09-03B-2 FUNCTION INOPERATIVE ..•........ 09-03B-5
KEYLESS ENTRY SYSTEM NO.2 TRANSMITTER ID CODE
PRELIMINARY INSPECTION ......•. 09-03B-3 CANNOT BE REPROGRAMMED ...•. 09-03B-7
KEYLESS ENTRY SYSTEM WIRING DIAGRAM

dcf090369000w01
B+ IG1
KEYLESS
CONTROL B+
MODULE
DOOR LOCK
CONTROL MODULE
DOOR
SWITCH
HAZARD
WARNING
SWITCH
THEFT-DETERRENT
CONTROL MODULE
DBR914ZWB002
FOREWORD
dcf090369000w02
• Go to troubleshooting after identifying the specific malfunction by performing a keyless entry system
preliminary inspection.
Flowchart
START
Interview customer using keyless

entry system check sheet
Keyless entry system

preliminary inspection
ZLU0903W001
09-038-1
KEYLESS ENTRY SYSTEM CHECK SHEET
dcf090369000w03
• Use the sheet below as a customer interview sheet when accepting a vehicle for service.
• If the symptom is "Power door lock system does not operate with transmitter at all;' find out how the customer
uses the keyless entry system by following the check sheet below.
Perform the following inspection with customer:

Q1. What's the customer's complaint?
D Power door lock system does not operate with transmitter (door does not lock/unlock).
DOther_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ ____
Q2. Is system factory-installed or after-market?

D Factory-installed system
-7 Go to Q3.
D After-market system
-7 Perform troubleshooting according to after-market keyless entry system manual.
Q3. Operate transmitter with customer from 2.5 m {8.2 ft} away from center of vehicle. (Make sure the ignition
key is either in the LOCK position or removed.)
Does keyless entry system work?
DYes
-7 Explain the following to the customer:
• Keyless entry system does not work when ignition switch is in ON position.
• Keyless entry system does not work from excessive distances (more than 2.5 m {8.2 ft} away from
center of vehicle}.
D No
-7 Go to Q4.
Q4. Check location where customer uses keyless entry system.

Does a particular area, such as being near TV towers, power plants, power lines, or factories, have an
effect on malfunction?
DYes Place_-:----:--:----:-=--:-:---=-__-:-_-::-:---:-_-::--_ _ _ _ _-:--_ _ _ _ _ _ _ _ __
-7Area of operation is bad. Explain effect of outside interferenc~ on transmitter to customer.
D No
-7 Go to Q5.
Q5. Make sure there are no after-market electrical parts installed on vehicle.
Are there any of the following present?
• Cellular phone
• Radio-wave equipment
• Remote engine starter
• TV, etc.
DYesParts _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ ___
D No
Perform the keyless entry system preliminary inspection.
ZLU0903W002
09-038-2
KEYLESS ENTRY SYSTEM PRELIMINARY INSPECTION
dcf090369000w04
• Perform the following preliminary inspection before troubleshooting.
1 • Is system an after-market one? Yes Perform troubleshooting according to after-market keyless
entry system manual.
No Go to next step.
2 • Did customer activate keyless entry system Yes Go to next step.
when ignition switch was in LOCK position? No • Explain to customer that system does not work when
ignition is in ON position.
• Turn ignition switch to LOCK position, then go to next
step.
3 • Did customer use keyless entry system in Yes Attempt to lock/unlock doors with transmitter in
particular area, such as being near TV non-interference area.
towers, power plants, power lines, or If system operates:
factories? • Area of operation is bad. Explain effect of outside
interference on transmitter to customer.
If system does not operate:
• Go to next step.
No Go to next step.
4 • Are any of the following after-market Yes Disconnect after-market electrical part connectors and
electrical parts on the vehicle? attempt to lock/unlock doors with transmitter.
- Cellular phone If system operates:
- Radio-wave equipment
- Remote engine starter
• After-market electrical parts are interfering with keyless
entry system.
-TV, etc. If system does not operate:
• Go to next step.
No Go to next step.
5 • Perform on-board diagnostic function. Yes Go to next step.
(See 09-03B-4 ON-BOARD DIAGNOSTIC No Go to Step 1 of NO.1 ON-BOARD DIAGNOSTIC
FUNCTION.) FUNCTION INOPERATIVE.
• Does on-board diagnostic function work?
6 • Attempt to reprogram transmitter ID code. Yes System is normal now.
• Can transmitter ID code be reprogrammed? No Go to Step 1 of troubleshooting NO.2 TRANSMITTER ID
CODE CANNOT BE REPROGRAMMED.
09-038-3
ON-BOARD DIAGNOSTIC FUNCTION
dcf090369000w05
1. Remove ignition key from steering lock.

2. Close all doors.
I Open driver-side door.
Note
• Perform the following procedures within 24 seconds.
- 1. Insert ignition key into steering lock.

2. Repeat the following 4 times.
• TL!rn ignition switch to ON position, then back to LOCK
position.
3. Remove ignition key from steering lock.
4. Push driver-side door switch 3 times.
~
Confirm the following operations in order every 1 second:
• All doors lock.
• Driver-side door unlocks. Yes On-board diagnostic function is operated
• Passenger-side and rear doors unlock. properly.
On-board diagnosis is completed.
Are above operations okay?
~ No
Did you conduct on-board diagnosis properly? Yes IOn-board diagnostic function is inoperative.
Perform symptom troubleshooting.
~ No
Wait for 40 seconds.
I Return
DBR903MWBOOl
TROUBLESHOOTING INDEX
dcf090369000w06

1 On-board diagnostic function Theft-deterrent control module's on- (See 09-038-5 NO.1 ON-80ARD
inoperative board diagnostic function does not DIAGNOSTIC FUNCTION
operate. INOPERATIVE.)
2 Transmitter 10 code cannot be Theft-deterrent control module's (See 09-038-7 NO.2 TRANSMITTER
reprogrammed transmitter 10 code reprogram function 10 CODE CANNOT 8E
does not work. REPROGRAMMED.)
09-038-4
NO.1 ON-BOARD DIAGNOSTIC FUNCTION INOPERATIVE
dcf090369000w07
• When performing an asterisked (*) troubleshooting inspection, shake the wiring harness and connectors while
performing the inspection to discover whether poor contact points are the cause of any intermittent
malfunctions. If there is a problem, check to make sure connectors, terminals and wiring harness are
1 On-board diagnostic function inoperative
DESCRIPTION Theft-deterrent control module's on-board diagnostic function does not operate.
POSSIBLE • Malfunction in door lock control module system
CAUSE • Malfunction in door lock linkage
• Malfunction in power door lock system
• Malfunction in theft-deterrent control module
• Malfunction in theft-deterrent control module power supply circuit
• Malfunction in theft-deterrent control module ground circuit
• Malfunction in IG1, B+ signal circuit of keyless control module
- keyless control module power supply fuse malfunction
- Malfunction in wiring harness between keyless control module power supply fuse(s) and keyless
control module itself
• Malfunction in keyless control module's door open/closed signal circuit
- Door switch, keyless control module malfunction
• Malfunction in keyless control module GND signal circuit
- Malfunction in wiring harness between keyless control module and ground
- Malfunction in wiring harness between keyless control module and door switch(es)
• Malfunction in keyless control module door lock/unlock signal circuit
- keyless control module malfunction
- Malfunction in wiring harness between keyless control module and theft-deterrent control module
1 INSPECT ON-BOARD DIAGNOSTIC Yes Go to next step.
FUNCTION OPERATION No Go to Step 7.
• Did any of the following items work during
on-board diagnostic function operation?
- All doors locked
- Driver's side door unlocked
- All doors unlocked
2 INSPECT DOOR LOCK LINKAGE SYSTEM Yes Go to next step.
• Operate inner door lock knob and make sure No Troubleshoot the door lock linkage.
door locks and unlocks manually.
• Do all door's lock systems work?
3 CHECK TO SEE WHETHER MALFUNCTION Yes Go to next step.
IS IN DOOR LOCK CONTROL MODULE, No Inspect power door lock system, then go to step 15.
DOOR LOCK ACTUATOR, A KEY CYLINDER
SWITCH AND RELATED WIRING HARNESS,
OR ELSEWHERE
• Do all of the following items work when
inserting ignition key into driver's door key
cylinder and operating ignition key?
- All doors locked
- All doors unlocked
4 INSPECT POWER DOOR LOCK SYSTEM Yes Replace keyless control module and reprogram transmitter
• Turn ignition switch to LOCK. ID code, then go to Step 15.
• Disconnect keyless control module No Inspect theft-deterrent control module and wiring harness
connector. (between keyless control module terminal 0, terminal K and
• Measure voltage at following keyless control theft-deterrent control module terminal Q)
module connector terminals.
- Terminal 0
-Terminal K
• Is voltage approximately 5 V?
5 INSPECT THEFT-DETERRENT CONTROL Yes Go to next step.
MODULE No Replace theft-deterrent control module, then go to Step 15.
• Turn ignition switch to LOCK position.
• Disconnect theft-deterrent control module
connector (24-pin)
• Measure voltage at theft-deterrent control
module connector (24-pin) terminal V.
• Is resistance approximately 1.3 kilohm?
09-038-5

6* INSPECT WIRING HARNESS BETWEEN Yes Repair wiring harness between keyless control module and
KEYLESS CONTROL MODULE AND THEFT- theft-deterrent control module, then go to Step 15.
DETERRENT CONTROL MODULE FOR No Replace keyless control module and reprogram transmitter
CONTINUITY AND SHORT ID code, then go to Step 15.
• Disconnect keyless control module
connector.
• Inspect wiring harness between keyless
control module connector terminal J and
theft-deterrent control module connector (24-
pin) terminal V.
• Is there open circuit and/or short circuit at
above wiring harness?
7 INSPECT KEYLESS CONTROL MODULE Yes Go to next step.
AND THEFT-DETERRENT CONTROL No Check for a short to ground on blown fuse's circuit. Repair or
MODULE POWER SUPPLY FUSES replace if necessary. Install appropriate amperage fuse.
• Are keyless control module and theft-
deterrent control module power supply fuses
okay?
8 INSPECT DOOR SWITCHES Yes Go to next step.
• Are door switches installed securely? No Install door switch(es) securely, then go back to Step 2 of
keyless entry system preliminary inspection.
9 INSPECT THEFT-DETERRENT CONTROL Yes Go to next step.
MODULE INSTALLATION No Install theft-deterrent control module securely, then go to
• Is theft-deterrent control module installed to Step 15.
joint box securely?
10* INSPECT WIRING HARNESS BETWEEN Yes Go to next step.
KEYLESS CONTROL MODULE POWER No Repair wiring harness between fuse block and keyless
SUPPLIES AND KEYLESS CONTROL control module, then go to Step 15.
MODULE FOR CONTINUITY
• Turn ignition switch to ON position.
• Measure voltage at following keyless control
module terminals:
-IG1 signal (Terminal A)
- B+ signal (Terminal 8)
11* INSPECT WIRING HARNESS BETWEEN Yes Repair malfunctioning wiring harness, then go to Step 15.
KEYLESS CONTROL MODULE POWER No Go to next step.
SUPPLY, KEYLESS CONTROL MODULE AND
GROUND FOR SHORT TO B+
connector.
• Measure voltage at following keyless control
module connector terminal A.
12* INSPECT WIRING HARNESS BETWEEN Yes Go to next step.
KEYLESS CONTROL MODULE AND No Repair wiring harness between keyless control module and
GROUND FOR CONTINUITY ground, then go.to Step 15.
• Is there continuity between keyless control
module connector terminal L and ground?
13* INSPECT WIRING HARNESS BETWEEN Yes Repair wiring harness between keyless control module and
KEYLESS CONTROL MODULE AND DOOR door switch or replace malfunction door switch, then go to
SWITCH FOR CONTINUITY AND SHORT Step 15.
• Turn ignition switch to LOCK position. No Go to next step.
connector.
• Inspect wiring harness between keyless
control module connector terminal C and
door switch connector terminal.
• Is there open circuit and/or short circuit at
above wiring harness?
09-038-6

14* INSPECT THEFT-DETERRENT CONTROL Yes Go to next step.
MODULE POWER SUPPLY SYSTEM FOR No Replace keyless control module and reprogram transmitter
CONTINUITY AND SHORT 10 code, then go to next step.
• Turn ignition switch to LOCK position.
• Remove theft-deterrent control module from
joint box.
• Turn ignition switch to ON position.
• Measure voltage at following theft-deterrent
control module (16-pin) terminals.
-Terminal C
• Does keyless entry system operate No Recheck malfunction symptoms, then repeat from Step 1 if
properly? malfunction recurs.
NO.2 TRANSMITTER 10 CODE CANNOT BE REPROGRAMMED

dcf09036900Ow08
2 Transmitter ID code cannot be reprogrammed.

DESCRIPTION Theft-deterrent control module's transmitter 10 code reprogram function does not work.
POSSIBLE • Malfunction in transmission circuit
CAUSE - Transmitter battery, transmitter, keyless control module bracket, keyless control module bracket
ground screw or keyless control module malfunction
1 INSPECT TRANSMITTER BATTERY Yes Go to next step.
INSTALLATION AND TYPE No Set transmitter battery properly or replace with specified
• Visually inspect transmitter battery. transmitter battery (CR2025), then go to Step 8.
• Are below items okay?
- Transmitter battery installation (correct
polarity)
- Battery type (CR2025)
2 INSPECT TRANSMITTER BATTERY Yes Replace transmitter battery or repair transmitter battery
TERMINALS FOR RUST AND POOR terminal, then go to Step 8.
CONNECTION No Go to next step.
• Visually inspect transmitter.
- Is there rust on transmitter battery
terminals (positive or negative pole)?
- Is there poor connection between
terminals and battery?
3 INSPECT TRANSMITTER BATTERY Yes Go to next step.
• Inspect transmitter battery. No Replace transmitter battery, then go to Step 8.
• Is battery voltage normal?
4 INSPECT KEYLESS CONTROL MODULE Yes Go to next step.
BRACKET INSTALLATION No Install bracket securely, then go back to Step 6 of keyless
• Is keyless control module bracket installed entry system preliminary inspection.
securely?
5 INSPECT GROUND SCREW INSTALLATION Yes Go to next step.
BETWEEN KEYLESS CONTROL MODULE No Install screw securely, then go back to Step 6 of keyless
AND KEYLESS CONTROL MODULE entry system preliminary inspection.
BRACKET
• Are keyless control module and keyless
control module bracket connected securely
to ground screw?
6 CHECK TO SEE WHETHER MALFUNCTION Yes Replace transmitter battery, then go to Step 8.
IS IN TRANSMITTER BATTERY OR No Go to next step.
ELSEWHERE
• Replace with a known good transmitter
battery.
• Does keyless entry system operate
properly?
09-038-7

7 CHECK TO SEE WHETHER MALFUNCTION Yes Replace transmitter and reprogram transmitter ID code,
IS IN TRANSMITTER OR KEYLESS then go to next step.
CONTROL MODULE No Replace keyless control module and reprogram transmitter
• Reprogram transmitter ID codes by using ID code, then go to next step.
another known good transmitter.
• Does keyless entry system operate okay?
• Does keyless entry system operate No Recheck malfunction symptoms, then repeat from Step 1 if
properly? malfunction recurs.
09-038-8
SYMPTOM TROUBLESHOOTING [IMMOBILIZER SYSTEM]
09-03C SYMPTOM TROUBLESHOOTING [IMMOBILIZER

SYSTEM]
SYMPTOM TROUBLESHOOTING No.1 SECURITY LIGHT DISPLAY IS
CHART [IMMOBILIZER SySTEM] .... 09-03C-1 NOT NORMAL .................... 09-03C-1
SYMPTOM TROUBLESHOOTING CHART [IMMOBILIZER SYSTEM]

dcf090367000w01
No. TROUBLESHOOTING ITEM DESCRIPTION

1 The security light display is not normal. • The security light remains illuminated 2 min or more after the ignition
switch is turned to the ON position
• The security light does not illuminate when the ignition switch is turned to
the ON position.
• The security light remains illuminated while the ignition switch is at the
LOCK position.
• The security light does not flash or the flashing interval is abnormal while
the ignition switch is at the LOCK position.
No.1 SECURITY LIGHT DISPLAY IS NOT NORMAL

dcf090367000w02
1 The security light display is not normal.

• The security light remains illuminated 2 min or more after the ignition switch is turned to the ON position
• The security light does not illuminate when the ignition switch is turned to the ON position.
DESCRIPTION • The security light remains illuminated while the ignition switch is at the LOCK position.
• The security light does not flash or the flashing interval is abnormal while the ignition switch is at the
LOCK position.
• Keyless unit malfunction
• Open or short circuit in the wiring harness between the instrument cluster and immobilizer unit
Note
• If the security light remains illuminated for approx. 1 min after the ignition switch is turned to the ON
position and then displays a DTC, perform immobilizer system malfunction diagnosis according to that
DTC. (See 09-02A-2 DTC TABLE [IMMOBILIZER SYSTEM].)
• While performing immobilizer system security access using the WDS, the security light does not
illuminate even if the ignition switch is turned to the ON position. Verify the illumination condition of the
POSSIBLE security light by disconnecting the DLC-2 to release security access.
CAUSE
NOTE: SECURITY LIGHT FLASHING SEQUENCE
WHEN IGNITION SWITCH IS TURNED TO LOCK POSITION
Jl
(IMMOBILIZER SYSTEM IS NORMAL)
::::':::EO tPPROX 19 S, ~ ,APPROX 1.9 ~ ~

.. ::..
II
APPROX. 0.1 S
09-03C-1
SYMPTOM TROUBLESHOOTING [IMMOBILIZER SYSTEM]
• Do other warning lights in the instrument cluster No Inspect the instrument cluster.
illuminate normally? (See 09-22-2 INSTRUMENT CLUSTER
INSPECTION.)
2 • Turn the ignition switch to the LOCK position. Yes Replace the instrument cluster.
• Disconnect the negative battery cable. (See 09-22-2 INSTRUMENT CLUSTER REMOVAU
• Disconnect the instrument cluster connector (24- INSTALLATION.)
pin). No Go to the next step.
• Does the security light illuminate?
3 • Disconnect the negative battery cable. Yes Go to the next step.
• Connect the instrument cluster connector. No Repair or replace the wiring harness for short to GND
• Disconnect the immobilizer unit connector between the immobilizer unit connector terminal M and
• Connect the negative battery cable. the instrument cluster terminal1J.
4 • Disconnect the negative battery cable. Yes Go to the next step.
• Ground instrument cluster terminal1J using a No Replace the instrument cluster.
jumper wire. (See 09-22-2 INSTRUMENT CLUSTER REMOVAU
• Connect the negative battery cable. INSTALLATION.)
5 • Disconnect the negative battery cable. Yes Replace the immobilizer unit.
• Connect the instrument cluster connector. (See 09-14-22 IMMOBILIZER UNIT REMOVAU
• Disconnect the immobilizer unit connector INSTALLATION. )
• Ground immobilizer unit connector terminal M No Repair or replace the wiring harness for short to GND
using a jumper wire. between the immobilizer unit connector terminal M and
• Connect the negative battery cable. the instrument cluster terminal1J.
09-03C-2
SYMPTOM TROUBLESHOOTING [AUDIO]
09-030 SYMPTOM TROUBLESHOOTING [AUDIO]

FOREWORD NO.3 NOISE FROM RADIO
[ENTIRE AUDIO SySTEM] ...•....•. 09-030-1 (FM ONLY) •.•.....•......•......• 09-030-14
CONFIRMATION STEP 1: NO.4 CANNOT TUNE
AUDIO PANEL SWITCH (SEEK DOES NOT STOP) .....•.•... 09-030-16
CONFIRMATION •••.•...•....•.... 09-030-3 NO.5 CANNOT PRESET
NO.1 AF NOISE OR POP NOISE ON (PRESET FUNCTION DOES NOT
ALL SOURCES (RADIO, CD) •.•..... 09-030-3 OPERATE) ...........••..•.•.•.•. 09-030-16
NO.2 NO POWER ON THE ENTIRE NO.6 RECEPTION FREQUENCY OF
AUDIO SYSTEM •....•.•.....••.•• 09-030-4 RADIO SLIPS •..•.••.••...•....... 09-030-17
NO.3 NO SOUND FROM ALL THE FOREWORD
SPEAKERS •.•....•.•.•.••.••.•.• 09-030-5 [CD PLAYER/CHANGER] ...•.•..... 09-030-17
NO.4 NO SOUND FROM SOME NO.1 CD PLAYER/CHANGER
SPEAKERS .•..•••.•...•...••..•. 09-030-6 DOES NOT LOAD THE CD OR
NO.5 BROKEN SOUND OR POOR EJECTS THE CD IMMEDIATELy ...... 09-030-19
SOUND QUALITY •.•••...•••••.•.. 09-030-7 NO.2 CD PLAYER/CHANGER
NO.6 SOUND BECOMES LOUDLY OR DOES NOT EJECT THE CO ..•..•.... 09-030-19
WEAKLY WHILE DRIVING THE NO.3 CD PLAYER/CHANGER
VEHICLE ..••...••.•............• 09-030-7 DOES NOT PLAY THE
NO.7 ALC FUNCTION IS CD/NO SOUND .....•...••.......•. 09-030-20
INOPERATIVE ..•.....•••....•..•. 09-030-8 NO.4 SOUND JUMPS ••.•....•.•..... 09-030-20
NO.8 AUDIO SYSTEM ILLUMINATION NO.5 CD PLAYER/CHANGER
DOES NOT ILLUMINATE AT ALL. .... 09-030-8 SCRATCHES ON THE CD ........... 09-030-21
NO.9 LCD DOES NOT DISPLAY NO.6 DISC CHANGER IS
AT ALL ....•....••••...•...•..... 09-030-9 INOPERATIVE ..•.••.............• 09-030-21
FOREWORD [RADIO] .....•..••..••. 09-030-9 NO.7 CD PLAYER DOES NOT PLAY
CONFIRMATION STEP 1: RECEPTION THE MP3-FORMATTEO FILE .•.....• 09-030-22
CONDITION SYMPTOM NO.8 MP3-FORMATTEO FILE FOLDER
(EXAMPLE) ...........••..••.•.•. 09-030-10 SELECTION IS INOPERATIVEITRACK
CONFIRMATION STEP 2: ANTENNA SEARCH IS INOPERATIVE ••...•.•.• 09-030-23
SYSTEM SYMPTOM (EXAMPLE) •... 09-030-11 NO.9 CD PLAYER DOES NOT
CONFIRMATION STEP 3: ANTENNA INDICATE THE MP3 TITLE TEXT ..... 09-030-24
SYSTEM SIMPLE INSPECTION •..... 09-030-11 NO.10 CD PLAYER DOES NOT PLAY
NO.1 NO RADIO RECEPTION THE AUDIO DATA (CODA) ..........• 09-030-24
(AM/FM)/NO OR LOW VOLUME •..... 09-030-11 NO.11 TRACK CHANGE IS
NO.2 NOISE FROM RADIO INOPERATIVE ...•...•.•...•.•.... 09-030-25
(AM ONLY) ....••..•....•••..•.••. 09-030-13 RADIO [REFERENCE] •.•....•....... 09-030-25
AUDIO CD [REFERENCE] •••.•..•.•.• 09-030-27
FOREWORD [ENTIRE AUDIO SYSTEM]

dcf09036690Ow01
Note
• Record all radio programs set by customer prior to the repairs. Set all radio programs and adjust the time
after repairs.
No. Symptom Possible DTC
1 AF noise or POP noise on all sources (Radio, CD) 09:Er20, 09:Er21
2 No power on the entire audio system 09:Er20
3 No sound from all the speakers OO:Er10, 03:Er07, 03:Er10, 09:Er20,
09:Er21
4 No sound from some speakers -
5 Broken sound or poor sound quality 09:Er21
6 Sound becomes loudly or weakly while driving the vehicle -
7 ALC function is inoperative -
8 Audio system illumination does not illuminate at all 09:Er20, 21 :Er19
9 LCD does not display at all 09:Er20, 21 :Er19
09-030-1
Quick Diagnostic Chart (Entire Audio System)
X: Applicable
1 2 3 4 5 6 7 8 9
Q)
C3
:.c
~
Troubleshooting item 5'
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Q)
:5
Cti
Cl Ci1
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'6 Ci1
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.!!1
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::> Cti >- c
0
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>-
C/)
::> :;2 C/)
0- t1l Q)
Cti 0
'6 ~t1l -0
c
Q)
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0
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c ::> ::> > c Cti
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Q)
a. 0 0 0
Q)
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C/)
C/)
>- ~Q) ~
1il
Possible factor
C/)
·0 E
Q) 00 '5
::> a. c ~
c Q) E
0 a. .2 0 ·E i5..
0... .!: C/)
0
Q)
:5 'ijj
C/)
0 C/)
Q)
.!!2
:§ =a
E E
0... c ,g -0
c c E (5
*
0 0 Ci1 ::> 0
() 0 c
Q) a; "0
c
-0
c
0
C/)
Q)
.c t5c >-
C/)
Q)
C/)
c 0
~ ::> ::> C/)
·0 0 0 Q) "0 .2 0 -0
C a. .::£ C
0
e '6
C/) C/)
::> ()
u.. 0 0 0 0 ....J ::> ()
« z z z co (J) « « ....J
Low vehicle battery voltage X

Jammed radio signals from after market equipment X
Speaker malfunction (e. g., any foreign material, broken) X X X X
Improper speaker installation X X
Poor connection of audio unit connector, terminal damage X X X X
Antenna malfunction (e.g., poor ground) X
Audio unit malfunction X X X X X X X X
Burnt fuse (B+) X
Burnt fuse (ACC) X
Open or short circuit in power supply (B+) wiring harness X
Open or short circuit in power supply (ACC) wiring harness X
Short circuit in wiring harness between audio unit and speaker X X
Open circuit in wiring harness between audio unit and speaker X
Short circuit inside speaker X X
Vibration of door trim and/or package trim X
CAN signal wiring harness malfunction X
Open or short circuit in vehicle speed signal wiring harness (e.g., instrument cluster) X
Burnt fuse (TNS signal) X
Open or short circuit in TNS signal wiring harness X
Center panel malfunction X
Information display malfunction X
DBG903AWBS01
09-030-2
CONFIRMATION STEP 1: AUDIO PANEL SWITCH CONFIRMATION
dcf090366900w02
• Make sure the customer complain and identify either the center panel malfunction or audio unit malfunction.
How to activate audio panel switch confirmation mode

1. Turn the audio system to ON.
2. Press both POWER SW and CLOCK buttons for a second at the same time.
3. The audio panel switch confirmation mode is now activated.
1 • Press each button on the center panel. Yes Make sure the customer complain and then go to the
• Does buzzer sound when pressing each appropriate symptom troubleshooting procedure.
button? No Go to the next step.
2 • Disassemble and reassemble the center Yes Go to the next step.
. panel and audio unit. No Replace the center panel.
• Activate the audio panel switch confirmation
mode.
• Does buzzer sound when pressing each
button?
3 • Does the audio system operate properly? Yes The system is normal.
No Make sure the customer complain and then go to the
appropriate symptom troubleshooting procedure.
NO.1 AF NOISE OR POP NOISE ON ALL SOURCES (RADIO, CD)

dcf090366900w03
1 IAF noise or POP noise on all sources (Radio, CD)/Possible DTC: 09:Er20, 09:Er21
Troubleshooting hints
• Low vehicle battery voltage
• Jammed radio signals from after market equipment
• Speaker malfunction (e.g., any foreign material, broken)
• Improper speaker installation
• Audio unit malfunction
• Poor connection of audio unit connector, terminal damage
• Antenna malfunction (e.g., poor ground)
Note
• AF noise is "Petit Petit" noise that generally occurs with switch ON/OFF operations of electrical equipment other than
the audio unit, or "Gee" continual noise that occurs when electrical equipment is operated.This is caused by noise
entrance to the power supply wiring, signal wiring, speaker cable or head of cassette deck etc. Therefore noise can be
heard regardless of radio wave condition or audio volume position. The noise will start after one click from the minimum
position of volume button but normally does not change even when volume is turned to higher position.
• POP noise is "Putsun", "Poco" or "Putsun" noise that occurs with switch ON/OFF operation of the audio unit, or with
switching Radio to CD. Even normal audio unit sometimes emit small noise depending on conditions.
• Inspect the vehicle battery voltage. Yes Go to the next step.
• Is the vehicle battery voltage normal? No Charge the battery, then go to the next step.
Specification:
Ignition switch ON: 11.5 V or more
Idle: 12.5 V or more
2 • Turn the audio system to ON. Yes Go to the next step.
• Is there any noise? No The system is normal. Explain to the customer that the
vehicle battery voltage was low.
3 • Is any of the following after-market Yes Go to the next step.
equipment installed? (Inspect especially near No Go to the Step 5.
the antenna.)
-Radar
- Remote engine starter
- Anti-theft device
-Other
4 • Remove the after-market equipment. Yes Go to the next step.
• Turn the audio system to ON. No The system is normal. The after-market electrical devices
• Is there any noise? might make a noise.
09-030-3

5 • Is there the noise from all speakers? Yes Go to the Step 7.
6 • Inspect the suspect speaker. Yes Go to the next step.
• Is the speaker normal? No If there is any foreign material on the speaker:
• Remove the foreign material from the speaker.
If the speaker is malfunctioning:
• Replace the speaker.
If the speaker is not installed properly:
• Install the speaker properly.
7 • Attempt to duplicate the symptom on the Yes Go to the next step.
other vehicle. No The system is normal. Explain the noise generation
• Is the noise better than the customer's mechanism to the customer.
vehicle?
Note
• The noise may be heard depends on the operating
speed of audio power and/or mode switch.
8 • Turn the ignition switch to the LOCK position. Yes Go to the next step.
• Remove the audio unit. No If poor connection of audio unit connector:
• Inspect the connection of the audio unit
• Securely connect the audio unit connector.
connector (24-pin) (for sound signal line).
If the audio unit side connector is wrong:
• Is the connector connected securely?
• Replace the audio unit.
If the wiring harness-side connector is wrong:
• Repair or replace the pins and/or the connector.
After treating either the above-mentioned, then go to the
next step.
9 • Is there any noise? Yes Go to the next step.
No The system is normal.
10 • Inspect the ground condition of the antenna. Yes Replace the audio unit.
• Is the ground condition normal? No Repair or replace the ground. Go to the next step.
11 • Is there any noise? Yes Replace the audio unit.
No The system is normal.
NO.2 NO POWER ON THE ENTIRE AUDIO SYSTEM

dcf090366900w04
2 INo power on the entire audio system/Possible OTC: 09:Er20

• Burnt fuse (B+)
• Burnt fuse (ACC)
• Open or short circuit in power supply (B+) wiring harness
• Open or short circuit in power supply (ACC) wiring harness
1 • Turn the ignition switch to the LOCK position. Yes Go to the next step.
• Inspect the following fuses: No Replace with the appropriate standard fuse.
-RADIO
-ROOM
• If the fuse is melted, inspect the wiring harness for short
to ground. Repair or replace the wiring harness, then
• Are the fuse normal? replace the fuse.
2 • Remove the audio unit. Yes Go to the next step.
• Inspect the connection of the audio unit No If poor connection of audio unit connector:
connector (24-pin).
• Disconnect the audio unit connector and
inspect both the audio unit and wiring
harness-side connectors for poor • Replace the audio unit.
connection. (such as damaged/pulled-out If the wiring harness-side connector is wrong:
pins, corrosion). • Repair or replace the pins and/or the connector.
- Terminal B (B+)
- Terminal R (ACC)
- Terminal W GND)
• Are all the pins normal?
09-030-4

3 • Connect the audio unit connector. Yes Go to the next step.
• Inspect the voltage for the power supply line No Repair or replace the suspect wiring harness.
(8+, ACC).
Specification:
Ignition switch ON: 11.5 V or more
Idle: 12.5 V or more
• Is the voltage normal?
4 • Turn the ignition switch to the LOCK position. Yes Replace the audio unit.
• Remove the audio unit connector (24-pin). No Repair or replace the wiring harness.
• Inspect the continuity between the audio unit
wiring harness-side connector terminal W
and the ground.
• Is there the continuity?
NO.3 NO SOUND FROM ALL THE SPEAKERS

dcf09036690Ow05
3 INo sound from all the speakers/Possible DTC: OO:Er10, 03:Er07, 03:Er10, 09:Er20, 09:Er21
• Short circuit in wiring harness between audio unit and speaker
• Short circuit inside speaker
• Press AUDIO CaNT button more than 1 Yes The system is normal.
second. No Go to the next step.
• Play the CD or Radio.
• Adjust the volume between "10" to "15".
• Is there the sound?
2 • Turn the ignition switch to the LOCK position. Yes Repair or replace the suspect wiring harness or speaker
• Remove the audio unit. unit.
• Disconnect the audio connector (24-pin).
• Inspect the continuity between the audio unit Note
wiring harness-side connector terminal and • If there is a short circuit between the speaker harness
ground: or speaker lead wire and ground, the protector circuit
For front speaker inside the audio unit operates to cut the sound.
- Terminal A (L+) - GND No Go to the next step.
- Terminal C (L-) - GND
- Terminal D (R+) - GND
- Terminal F (R-) - GND
For rear speaker
- Terminal S (L+) - GND
- Terminal U (L-) - GND
- Terminal V (R+) - GND
- Terminal X (R-) - GND
- Is there a continuity?
3 • Remove the speaker. Yes Replace the speaker.
• Disconnect the speaker connector (2-pin). No Replace the audio unit.
• Inspect the continuity between the speaker
wiring harness-side connector (2-pin)
terminal and ground:
For each speaker
- Terminal A - GND
- Terminal 8 - GND
09-030-5
NO.4 NO SOUND FROM SOME SPEAKERS
dcf090366900w06
4 INo sound from some speakers/Possible OTC: -

• Short circuit inside speaker
• Open or short circuit in wiring harness between audio unit and speaker
1 • Turn the audio unit to ON. Yes If no sound from some speaker:
• Press AUDIO CO NT button more than one • Go to the next step.
second (BAUFAD cancel mode). If no sound at all:
• Press both POWER and AUTO-M buttons • Go to the troubleshooting of "No.3 No sound from all
more than 1 second at the same time. speakers".
Note No The troubleshooting is completed.
• The sounded speaker now changes in
the order of left - front speaker, right
- front speaker, right - rear speaker
and left - rear speaker.
• Is there any speaker with no sound?

2 • Turn the ignition switch to the LOCK position. Yes Repair or replace the suspect wiring harness or speaker
• Disconnect the audio unit connector (24-pin). unit.
• Inspect the continuity between the audio unit
wiring harness-side connector (24-pin) Note
terminal and ground. • If there is a short circuit between the speaker harness
• Is there the continuity? or speaker lead wire and ground, the protector circuit
inside the audio unit operates to cut the sound.
3 •Remove the suspect speaker. Yes Replace the audio unit.
•Disconnect the speaker connector (2-pin) No Go to the next step.
and inspect the resistance of speaker.
• Is the resistance normal?
Specification
Speaker resistance + wiring harness
resistance
4 • Inspect the wiring harness between the Yes Go to the next step.
audio unit and the suspect speaker. No Repair or replace the suspect wiring harness.
5 • Inspect the suspect speaker. Yes Replace the audio unit.
• Is the speaker normal? No Go to the next step.,
Note
•If the speaker lead wire contacts to either
ground or vehicle frame, replace the
speaker.
09-030-6
NO.5 BROKEN SOUND OR POOR SOUND QUALITY
dcf090366900w07
5 IBroken sound or poor sound quality/Possible DTC: 09:Er21

• Improper speaker installation
• Vibration of door trim and/or package trim
1 • Are there a broken sound or poor sound Yes Go to the next step.
quality from all speakers? No Go to the Step 5.
2 • Inspect the sound while adjusting the sound Yes Go to the next step.
volume. No The system is normal.
• Is there a broken sound or poor sound
quality between "15" and "20"?
3 • Inspect the BASSITREB. Yes Go to the next step.
• Is there a poor sound quality at "-3 - +3" of No If there is a broken sound at "+6- -6" of BASSITREB with
"BASSITREB"? the maximum volume, the system is normal.
Note
• When press the AUDIO CONT button for
a few seconds, BASSITREB is set at "0".
4 • Attempt to duplicate the symptom on the Yes Replace the audio unit.
other vehicle. No The system is normal.
• Is the sound better than the customer's
vehicle?
5 • Identify the speaker with a broken sound by Yes Go to the Step 7.
adjusting BAUFADE. No Go to the next step.
• Is the suspect speaker installed upward?
6 • Inspect the speaker installation condition. Yes Go to the next step.
• Is the speaker installed properly? No Install the speaker properly.
7 • Remove the speaker. Yes Repair or replace the suspect speaker.
• Is there any foreign material or damage on No Go to the next step.
the speaker?
8 • Inspect the sound again. Yes Go to the next step.
• Is there broken sound? No Inspect the vibration from the door trim and/or package trim.
Repair or replace the suspect trim as necessary.
9 • Replace with the speaker known to be good. Yes Replace the audio unit.
(e.g., swap right and left speakers) No Replace the speaker.
• Does the broken sound appear at the same
location?
NO.6 SOUND BECOMES LOUDLY OR WEAKLY WHILE DRIVING THE VEHICLE

dcf090366900w08
6 Sound becomes loudly or weakly while driving the vehicle/Possible DTC: -

Note
• Inspect the ALC function while driving the vehicle with playing the CD, etc.
• Does the ALC function turn to ON? Yes Go to the next step.
No Replace the audio unit.
2 • Turn the ALC fur,ction to OFF. Yes Replace the audio unit.
• Does the sound change while driving the No The system is normal. Explains the ALC function to the
vehicle? customer.
09-030-7
NO.7 ALC FUNCTION IS INOPERATIVE
dcf090366900w09
7 I ALC function is inoperative/Possible OTC: -

• CAN signal wiring harness malfunction
• Open or short circuit in vehicle speed signal wiring harness (e. g., instrument cluster)
Note
• Inspect the ALC function while driving the vehicle with playing the CD, etc.
1 • Turn the ALC function to ON. Yes The system is normal. Explains the ALC function to the
• Inspect the ALC function operation when customer.
driving the vehicle. No Go to the next step.
• Does the ALC system operate properly?
2 • Retrieve the DTCs from all vehicle modules Yes Go to the appropriate DTC inspection.
using the WDS or equivalent. No Replace the audio unit.
• Is there the following DTC displayed?
- Vehicle speed signal wiring harness
- CAN signal wiring harness
NO.8 AUDIO SYSTEM ILLUMINATION DOES NOT ILLUMINATE AT ALL

dcf090366900w10
8 I
Audio system illumination does not illuminate at alVPossible OTC: 09:Er20, 21 :Er19
• Burnt fuse (TNS signal)
• Open or short circuit in TNS signal wiring harness
• Center panel malfunction
1 • Are all illumination on the audio unit turned Yes Go to the next step.
OFF? No Replace the center panel.
2 • Turn the ignition switch to the LOCK position. Yes Go to the Step 4.
• Inspect the fuse (ILLUMI). No Go to the next step.
• Is the fuse normal?
3 • Turn the ignition switch to the LOCK position. Yes Repair or replace the short circuit in the suspect wiring
• Disconnect the audio unit connector (24-pin) harness. After repair the harness, replace with the
and inspect the continuity between the audio appropriate standard fuse.
unit wiring harness-side connector terminal E No Go to the next step.
(TNS) and the ground.
4 • Inspect the connection of the audio unit Yes Go to the next step.
connector (24-pin). No If poor connection of audio unit connector:
• Inspect both the audio unit and wiring
harness-side conne9tor terminal E for poor
connection (such as damaged/pulled-out
pins, corrosion). • Replace the audio unit.
• Are all the pins normal? If the wiring harness-side connector is wrong:
5 ,. Connect the audio unit connector (24-pin). Yes

• Repair or replace the pins and/or the connector.
Replace the audio unit.
• Turn the ignition switch to the ACC position. No Repair or replace the suspect wiring harness (TNS signal).
• Inspect the voltage at the audio unit
connector terminal E (TNS).
• Is the voltage B+ when the light switch is
turned to the TNS position?
09-030-8
NO.9 LCD DOES NOT DISPLAY AT ALL
dcf090366900w11
9 ILCD does not display at all/Possible DTC: 09:Er20, 21 :Er19

• Information display malfunction
1 • Turn the audio unit to ON. Yes Go to the next step.
• Press both POWER ON/OFF and SEEK UP No Replace the information display.
buttons for 0.2 seconds at the same time.
• Does the LCD display properly?
2 • Press either CLC or SET/INFO button on the Yes Replace the audio unit.
information display. No Replace both audio unit and information display.
• Does the beep sound? (CAN communication malfunction)
FOREWORD [RADIO]
dcf090366900w12
Note
• In case location, time, and broadcasting station etc. can be specified through interview to customer,
possibility that signal environment causes problem is high.
• Perform confirmation of symptom and evaluation under conditions that customer reported (location, time,
broadcasting station etc.). If not possible, perform it under equivalent conditions.
• Before inspection or repair, record the broadcasting stations that customer preset and reset them
accordingly after the inspection or repair. Adjust the clock too.
No. Symptom Possible DTC
1 No radio reception (AM/FM)/No or low volume 09:Er20, 09:Er22
2 Noise from radio (AM only) 09:Er22
3 Noise from radio (FM only) 09:Er22
4 Cannot tune (SEEK does not stop) 09:Er20, 09:Er22
5 Cannot preset (preset function does not operate) 21 :Er19
6 Reception frequency of radio slips 09:Er22
09-030-9
Quick Diagnostic Chart (Radio)
X: Applicable
1 2 3 4 5 6
Q)
Ol "§
E Ol
Troubleshooting item ::J 0..
0
(5
> 0
~ c
..Q (f)
Ol
5 02 0 (f)
.9-
Possible factor
0
z;;::,.. ~ "0
c "iii
0c 0 0
2 ;;:; >: t5c '0
u. c0 c0 (f) ~
~
Ol
0
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(f)
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0 0 0 UJ S, Ol
E. '0 '0 ~ Q5
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0-
Ol
() ~ ~ Ol
c
(f) ,g
~ E E ~ c
0
'0
,g ,g ~
0
0..
0c
0
li
~ Ol Ol c Ol
(f) (f) c c ()
0 ·0 ·0 tll tll Ol
Z Z Z () () a::
Jamming from aftermarket electronic equipment (two-way radio, navigation system, mobile phone, etc) X X X
Audio unit X X X X X X
Antenna plug poor connection X X X X
Antenna feeder X X X X
Electronic jamming from outside, or inferior condition of broadcasting station radio wave X X X X X
Antenna rod not installed X X X X
Noise from electrical system on vehicle (e.g. fuel pump) X X
Battery X X
Charging system X X
Antenna installation loosened X X
Center panel X X
DPE903EW1003
CONFIRMATION STEP 1: RECEPTION CONDITION SYMPTOM (EXAMPLE)

dcf09036690Ow13
Symptom Antenna signal condition Source

Only a buzzing sound from • There is no broadcasting wave. • Electric noise caused by the operation of
the speakers • Signals from antenna to audio unit are not internal circuit from audio unit itself
transmitted. • Atmosphere noise
A buzzing or crunching sound • Though signals are transmitted from • Electrical noise caused by operation of
and normal sound produced antenna to audio unit, electric noise from electrical component on vehicle
at the same time from the other sources is larger. • Electrical noise from high tension wire,
speakers transformer substation (factory), electrical
feeder line (street car), or motorcycle.
A thumping sound and normal • Noise occurs due to radio wave • Interference between direct and reflected
sound produced at the same environment at specific places (e.g. in waves of FM signals causes noise
time from the speakers (FM valleys between buildings). Noise varies (Multipass noise).
only) when own vehicle or surrounding vehicles
moves. (FM only)
09-030-10
CONFIRMATION STEP 2: ANTENNA SYSTEM SYMPTOM (EXAMPLE)
dcf09036690OW14
Possible cause AM reception condition FM reception condition

• Antenna feeder axis, open circuit NG: No reception YES: Reception possible.
• Antenna feeder plug not attached (Sensitivity decreases, but reception is
possible under strong electric field.)
• Antenna feeder axis (+) to ground (-), open circuit NG: No reception NG: No reception
• Antenna feeder and antenna, poor ground YES: Reception possible YES: Reception possible
(Noise may occur) (Sensitivity decreases, but reception is
possible under strong electric field.)
• Antenna feeder, jack and plug poor connection NG: No reception YES: Reception possible
(Depending on connection (Depending on connection conditions)
conditions)
CONFIRMATION STEP 3: ANTENNA SYSTEM SIMPLE INSPECTION

dcf090366900w15
Note
• Because the antenna system is equipped with a capacitor, the continuity cannot be checked. Therefore
proceed the following simple inspection.
1. Turn the AM radio on.
2. Tune to the frequency that there is no broadcast and you will hear a buzzing sound.
3. Turn a work light on and shake it around the antenna rod (around 10-20 mm)
4. If a whirring sound from the speaker synchronized to the work light movement is confirmed, the
antenna system is normal.
Note
• Use a fluorescent light type for the
inspection. Accurate diagnostic cannot be
done with an incandescent light.
CPJ902EWB011
NO.1 NO RADIO RECEPTION (AM/FM)/NO OR LOW VOLUME

dcf090366900w16
1 No radio reception (AM/FM)/no or low volume/Possible DTC: 09:Er20, 09:Er22

• Jamming from aftermarket electronic equipment (two-way radio, navigation system, mobile phone, etc.)
POSSIBLE • Antenna plug poor connection
CAUSE • Antenna feeder malfunction
• Electronic jamming from outside, or inferior condition of broadcasting station radio wave
• Antenna rod is not installed
• Turn the audio unit ON. Yes Go to the Step 3.
• Is the LCD indicated correctly? No Go to the next step.
2 • Measure voltage at B+ and ACe terminals. Yes Go to the next step.
• Is voltage okay? No Follow diagnostic procedure for symptom No.2 (Entire
Specification audio system).
With ignition switch ON: 11.5 V or more
At idling: 12.5 V or more
3 • Set volume to 10 to 15. Yes Go to the next step.
• Is buzzing sound or voice confirmed? No Follow diagnostic procedure for symptom NO.3 (Entire
audio system) or NO.4 (Entire audio system).
09-030-11

4 • Tune to local broadcasting station and check Yes Go to the next step.
reception condition. No Go to the Step 6.
• Is reception okay?
5 • Push PRESET buttons and check preset Yes The system is normal.
conditions. No Preset broadcasting stations.
• Has preset been stored?
6 • Is aftermarket electronic equipment (two-way Yes Go to the next step.
radio, navigation system, mobile phone, etc.) No Go to the Step 8.
installed?
Note
• TV antenna located closely to audio
antenna can be cause of noise. Relocate
TV antenna.
7 • Remove aftermarket electronic equipment. Yes The system is normal.
• Turn audio unit ON and check reception (Explain to customers that aftermarket electronic equipment
condition. is cause of noise)
• Is reception improved? No Go to the next step.
8 • Refer to confirmation step 3, and inspect Yes Replace audio unit.
antenna system. No Go to the next step.
• Is a whirring sound present?
9 • Inspect antenna plug connection condition. Yes Go to the next step.
• Is connection okay? No Insert antenna plug securely.
10 • Turn ignition switch to LOCK position. Yes Replace antenna feeder.
• Measure continuity between antenna feeder No Go to the next step.
axis and ground.
11 • Compare reception with other audio unit on Yes The system is normal.
same model (model/unit) under same (It is caused by electronic jamming from outside, or inferior
problem conditions. broadcasting station signal condition.)
• Is reception equivalent between customer's No Replace audio unit.
unit and compared unit?
Note
• Due to following differences, you may feel
difference in reception efficiency.
(Vehicle side factor)
- Antenna installation location, height,
feeder wiring routing, optional electrical
equipment
(Audio unit factor)
- Volume concern type: It decreases
change of volume when signals
become weak. (Noise is easy to be
conspicuous)
- Noise decrease type: It decreases
volume when signals become weak, so
that noise is not conspicuous.
09-030-12
NO.2 NOISE FROM RADIO (AM ONLY)
dcf090366900w17
2 Noise from radio (am only)/Possible OTC: 09:Er22

• Antenna rod not installed
• Noise from electrical system on vehicle (e.g. fuel pump)
• Battery malfunction
POSSIBLE • Charging system malfunction
CAUSE • Audio unit malfunction
• Antenna plug poor connection
• Antenna feeder malfunction
• Antenna installation loosened
1 • Tune to local broadcasting station and check Yes Tune to correct frequency of broadcasting station.
reception condition. If not preset, preset it.
• Is reception okay? No Go to the next step.
2 • Inspect antenna rod condition. Yes Go to the next step.
• Is antenna rod installed? No Advise customer to install antenna rod when radio is used.
installed?
Note
• TV antenna located closely to audio
antenna can be cause of noise. Relocate
TV antenna.
4 • Remove aftermarket electronic equipment. Yes The system is normal. (Explain to customers that
• Turn audio unit ON and check reception aftermarket electronic equipment is cause of noise)
condition. No Go to the next step.
• Is reception improved?
5 • Measure battery voltage. Yes Go to the next step.
• Is battery voltage okay? No Charge battery. Inspect charging system, and repair or
Standard replace if necessary.
Note
• Inspect that battery cables are connected
to terminals securely.
6 • Is noise occurring only when vehicle Yes Go to the next step.
electrical system (e.g. fuel pump) operates? No Go to the Step 8.
Note
• Identify subject electrical component by
disconnecting fuse, turning switch ON &
OFF, or disconnecting & connecting
connector.
• It will be easy when simulation function on
WDS is used.
7 • Inspect power supply, ground condition, and Yes Go to the next step.
noise prevention capacitor for electrical No Troubleshooting completed.
component.
• Is noise present after inspection? Note
Note •The audio unit supplies 12 V battery power to the
antenna amplifier for the AM radio reception in the
• Inspect following: radio mode. The audio unit cannot receive the AM
- Power supply to electrical component signals without the 12 V battery power to the antenna
for voltage drop (compare with battery amplifier. If the AM signals become strong, the audio
voltage) unit may receive the signal with noises.
- Resistance between ground of
electrical component and body.
(Should be close to 0 ohm)
- Installation condition of noise
prevention capacitor for fuel pump etc.
09-030-13

axis and ground.
10 Compare reception with other audio unit on Yes The system is normal (It is caused by electronic jamming
same model (model/unit) under same problem from outside, or inferior broadcasting station signal
conditions. condition).
• Is reception equivalent between customer's No Go to the next step.
Note
• Due to following differences, you may feel
difference in reception efficiency.
(Vehicle side factor)
- Antenna installation location, height,
feeder wiring routing, optional electrical
equipment
(Audio unit factor)
- Volume concern type: It decreases
change of volume when signals
become weak. (Noise is easy to be
conspicuous)
- Noise decrease type: It decreases
volume when signals become weak, so
that noise is not conspicuous.
11 • Retighten ground fixation for antenna Yes Replace audio unit.
installation part and antenna amplifier. No Troubleshooting completed.
Retighten antenna rod.
• Is noise present, after retightening?
NO.3 NOISE FROM RADIO (FM ONLY)

dcf090366900w18
3 Noise from radio (FM only)/Possible OTC: 09:Er22

• Noise from electrical system on vehicle (e.g. fuel pump)
• Battery malfllnction
• Charging system malfunction
POSSIBLE • Antenna plug poor connection
CAUSE • Antenna feeder malfunction
• Antenna installation loosened
Note
•FM broadcast has feature "sound quality is good" and "resistant to noise", but FM broadcast has
particular noises. Though audio unit is designed to reduce noise, there are times noise occurs due to
conditions.
1 • Tune to local broadcasting station and check Yes Tune to correct frequency of broadcasting station.
reception condition. If not preset, preset it.
• Is reception okay? No Go to the next step.
2 • Inspect antenna rod condition. Yes Go to the next step.
• Is antenna rod installed? No Advise customer to install antenna rod when radio is used.
installed?
09-030-14

4 • Remove aftermarket electronic equipment. Yes The system is normal. (Explain to customers that
• Turn audio unit ON and check reception aftermarket electronic equipment is cause of noise)
condition. No Go to the next step.
• Is reception improved?
5 • Measure battery voltage. Yes Go to the next step.
• Is battery voltage okay? No Charge battery. Inspect charging system, and repair or
Standard replace if necessary.
Note
• Inspect that battery cables are connected
to terminals securely.
6 • Is noise occurring only when vehicle Yes Go to the next step.
electrical system (e.g. fuel pump) operates? No Go to the Step B.
Note
• Identify subject electrical component by
disconnecting fuse, turning switch ON &
OFF, or disconnecting & connecting
connector.
• It will be easy when simulation function on
WDS is used.
7 • Inspect power supply, ground condition, and Yes Go to the next step.
noise prevention capacitor for electrical No Troubleshooting completed.
component.
• Is noise present after inspection?
Note
• Inspect following:
- Power supply to electrical component
for voltage drop (compare with battery
voltage)
- Resistance between ground of
electrical component and body.
(Should be close to 0 ohm)
- Installation condition of noise
prevention capacitor for fuel pump etc.
B • Inspect antenna plug connection condition. Yes Go to the next step.
axis and ground.
10 • Compare reception with other audio unit on Yes The system is normal (It is caused by electronic jamming
same model (model/unit) under same from outside, or inferior broadcasting station signal
problem conditions. condition).
• Is reception equivalent between customer's No Go to the next step.
11 • Retighten ground fixation for antenna Yes Replace audio unit.
installation part and antenna amplifier. No Troubleshooting completed.
Retighten antenna rod.
• Is noise present, after retightening?
II
Note
• When antenna is not grounded perfectly,
FM particular noise is likely to be
conspicuous.
09-030-15
NO.4 CANNOT TUNE (SEEK DOES NOT STOP)
dcf090366900w19
4 Cannot tune (seek does not stop)/Possible DTC: 09:Er20, 09:Er22

• Center panel malfunction
• Antenna plug poor connection
POSSIBLE • Antenna feeder malfunction
CAUSE • Audio unit malfunction
1 • Inspect if feel of SEEK button is normal when Yes Go to the next step.
button is pushed and released. No Perform confirmation step 1: audio panel switch
• Is it okay? confirmation. Replace center panel if necessary.
2 • Inspect indication of LCD. Yes Go to the next step.
• Is frequency indication increased or No Perform confirmation step 1: audio panel switch
decreased when SEEK button is pushed? confirmation. Replace center panel if necessary.
3 • Manually tune to local broadcasting station Yes Go to the Step 6.
and check reception condition. No Go to the next step.
• Is reception okay?
axis and ground.
6 • Check if number of broadcasting stations Yes The system is normal. (Explain to customer that SEEK
changes depending on time and place. sometimes does not stop depending on signal reception
• Does it change? condition.)
Note
• Signals tend to reach longer distances in the night. It
is conspicuous in AM signals, several audio functions
may stop due to foreign broadcasting station or noise.
Though the audio system restrains sensitivity of
SEEK and SCAN functions in the night, the audio
system may select other than desired broadcasting
station when signals are considerably strong.This
function is linked to the parking light. When the
parking light or headlight is turned on, SEEK and
SCAN may not function for weak signals.
No Replace audio unit.
NO.5 CANNOT PRESET (PRESET FUNCTION DOES NOT OPERATE)

dcf090366900w20
5 Cannot preset (preset function does not operate)/Possible DTC: 21 :Er19

POSSIBLE • Audio unit malfunction
CAUSE • Center panel malfunction
1 • Tune to desired station and push channel Yes Go to the next step.
preset button 1 for about 2 seconds to store No Go to the Step 3.
it.
• Repeat above for other stations using
channel preset buttons 2 to 5.
• Push channel preset butto., 1 to 6 one by
one.
• /l.re stored stations present?
2 • Turn ignition switch to LOCK and then to Yes The system is normal. (Explain preset procedure to
ACC. customer using Owner's Manual)
• Check if preset stations are stored by No Replace audio unit.
pushing preset buttons.
• Are stations stored?
09-030-16

3 • Remove center panel from audio unit, and Yes Replace audio unit.
reinstall center panel to audio unit. No Replace center panel.
• Turn audio power switch ON.
• Push POWER SW button and MEDIA button
at same time for approximately 1 second to
enter system to switch check mode.
• Push all buttons and check if buzzer sounds.
• Is all buttons okay?
NO.6 RECEPTION FREQUENCY OF RADIO SLIPS

dcf09036690OW21
6 Reception frequency of radio slip/Possible DTC: 09:Er22

POSSIBLE • Audio unit malfunction
CAUSE • Electronic jamming from outside, or inferior condition of broadcasting station radio wave
1 • Push SEEK button and check if desired Yes Go to the Step 3.
broadcasting station is tuned. No Go to the next step.
• Is it okay?
2 • Check if other broadcasting station is Yes Go to the next step.
received at certain place when indication of No Replace audio unit.
reception frequency stays.
• Is other station received?
Note
•When you receive weak signal from one
broadcasting station and come close to
broadcasting antenna which emits strong
signal, broadcasting with strong signal is
sometimes received.
3 • Compare reception with other audio unit on Yes Troubleshooting completed (Audio unit is normal).
same model (model/unit) under same No Replace audio unit.
problem conditions.
• Is reception equivalent between customer's
FOREWORD [CD PLAYER/CHANGER]

dcf090366900w22
No. Items Symptom Possible DTC
1 CD player/changer CD player/changer does not load the CD or ejects the 03:Er01, 03:Er1 0
CD immediately
2 CD player/changer does not eject the CD 03:Er01
3 CD player/changer does not play the CD/No sound 03:Er07, 03:Er10
4 Sound jumps 03:Er02
5 CD player/changer scratches on the CD 03:Er02
6 CD changer Disc changer is inoperative -
7 MP3 applicable CD player does not play the MP3-formatted file 10:Er09, 22:Er09
8 CD player MP3-formatted file folder selection is inoperativelTrack 10:Er09,22:Er09
search is inoperative
9 CD player does not indicate the MP3 title text -
10 CD player does not play the audio data (CODA) -
11 CD player/changer Track change is inoperative 03:Er02
09-030-17
X: Applicable
0;
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>:::
CD player/changer C. CD player 0>
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1 2 3 4 5 6 7 8 9 10 11
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00-00 GENERAL INFORMATION

VEHICLE IDENTIFICATION NUMBER (VIN) CODE

1 - ._ _ _ _ _ _ _ _ _ _ -..:...P..:.:la:..:.;..nt W=A. A. Thailand

1=WL-C (2.5 L-DI)

D= 2268-2721 kg {5001--6000 Ibs}

L--_ _ _ _ _ _ _ _ _ _ _ _ _ _ Product ~~~~

World manufacturer identification MNB= FORD (Thailand)

HOW TO USE THIS MANUAL DCFOOOOOOOOOB03

223 365 598 23.54) 84{22.99 t 1 489 358 150

Shows point name

J Cabin mounting bracket II l;jXlo

Shows point symbol

Shows point name

@ Center elliptical hole Center of rectangular-shaped hole

G)6iJ Notch Edge of rectangular-shaped hole

./ Panel seam, bead, etc.

09-800 BODY STRUCTURE [DIMENSIONS]

~I§ 1:":1 I~I! ~ l> -I

Hole diameter Hole diameter

Hole diameter Hole diameter

Hole diameter Hole diameter

Hole diameter Hole diameter

Hole diameter Hole diameter

Hole diameter Hole diameter

BODY STRUCTURE [DIMENSIONS]

Hole diameter Hole diameter

Hole diameter Hole diameter

BODY STRUCTURE [DIMENSIONS]

BODY STRUCTURE [DIMENSIONS]

Hole diameter Hole diameter

Hole diameter Hole diameter

BODY STRUCTURE [DIMENSIONS]

Hole diameter Hole diameter

GENERAL INFORMATION ... 00-00

00-00 GENERAL INFORMATION

FRONT SHOCK ABSORBER

TORSION BAR SPRING

STEERING COLUMN AND SHAFT

STEERING GEAR AND LINKAGE

DRIVE PINION GEAR

DRIVE PINION GEAR

REAR BRAKE (DRUM)

~ ASS CONTROL MODULE (CM)

G SENSOR (Hi-Rider, 4x4)

FRONT ASS WHEEL-SPEED

TSS SENSOR ISS SENSOR LOW/REVERSE

OVERDRIVE ONE- INTERMEDIATE CONTROL VALVE

COUNTER REVERSE GEAR REVERSE IDLER GEAR

VEHICLE IDENTIFICATION NUMBER (VIN) CODE

ModelYesr 7= 2007, 8=2008, 9=2009 .. .

Gulf: Check Digit o to 9, X

Gulf only Other

Gulf only Others

M= Thailand (for Europe (L.H.D.))

WFO=FORD (European (L.H.D.))

Electrical current A (ampere)

Positive pressure kgf/cm 2 (kilogram force per square

Conversion to SI Units (Systeme International d'Unites)