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RANG.DRFT.REPAIR MANUAL

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Ranger / Drifter Repair Manual
FOREWORD
This Manual has been prepared to provide information covering normal service repairs and maintenance for the RANGER / DRIFTER SERIES. As all information in this manual was the best available at the time of printing, vehicle specification and other information will be updated in Service Information.

Ford/Mazda Motor Company

WARNING
Servicing a vehicle can be dangerous. If you have not received service-related training, the risks of injury, property damage, and failure of servicing increase. The recommended servicing procedures for the vehicle in this workshop manual were developed with Ford/Mazda-trained technicians in mind. This manual may be useful to non-Ford/Mazda trained technicians, but a technician with our service-related training and experience will be at less risk when performing service operations. However, all users of this manual are excepted at least to know general safety procedures. This manual contains "Warnings" and "Cautions" applicable to risks not normally encountered in a general technician's experience. They should be followed to reduce the risk of injury and the risk that improper service or repair may damage the vehicle or render it unsafe. It is also important to understand that the "Warnings" and "Cautions" are not exhaustive. It is impossible to warn of all the hazardous consequences that might result from failure to follow the procedures. The procedures recommended and described in this manual are effective methods of performing service and repair. Some require tools specifically designed for a specific purpose. Persons using procedures and tools, which are not recommended by Ford/Mazda Motor Corporation, must satisfy themselves thoroughly that neither personal safety nor safety of the vehicle will be jeopardized. The contents of this manual, including drawings and specifications, are the latest available at the time of printing, and Ford/Mazda Motor Corporation reserves the right to change the vehicle designs and alter the contents of this manual without notice and without incurring obligation. Parts should be replaced with genuine Ford/Mazda replacement parts or with parts, which match the quality of genuine Ford/Mazda replacement parts. Persons using replacement parts of lesser quality than that of genuine Ford/Mazda replacement parts must satisfy themselves thoroughly that neither personal safety nor safety of the vehicle will be jeopardized. Ford/Mazda Motor Corporation is not responsible for any problems, which may arise from the use of this manual. The cause of such problems includes but is not limited to insufficient service related training, use of improper tools, use of replacement parts of lesser quality than that of genuine Ford/Mazda replacement parts, or not being aware of any revision of this manual.

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CONTENTS
Title General Information Section GI GI G6 Engine F8/FE WL, WL Turbo F2 Lubrication System Cooling System G6 Fuel and Emission Control Systems WL, WL Turbo F2 CIS F2 CARB Engine Electrical System Clutch M15M–D M15MX–D R15M–D R15MX–D Transfer Propeller Shaft Front and Rear Axles Steering System Braking System Suspension Body Body Electrical System Heater and Air Conditioner Systems Technical Data Special Tools B2 B3 D E F1 F2 F3 F4 G H J1 J2 J3 L M N P R S T U TD
ST ST

Ranger / Drifter Repair Manual

B1

APPLICATION: This manual is applicable to vehicles beginning with the Vehicle Identification Numbers (VIN), and related materials shown on the following page.

Manual Transmission

1999 Ford/Mazda Motor Company All rights reserved. Reproduction by any means, electronic or mechanical including photocopying, recording or by any information storage and retrieval system or translation in whole or part is not permitted without written authorization from Ford/Mazda Motor Company. PRINTED IN JAPAN, JAN.1999 F161–10–99A

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VEHICLE IDENTIFICATION NUMBERS (VIN)
U.K. specs.
JMZ JMZ JMZ JMZ JMZ JMZ JMZ JMZ JMZ JMZ JMZ UN1B320W UN8B320W UN8F420W UN1*620W UN1*62WW UN1*320W UN1*32WW UN8*720W UN8*72WW UN8*320W UN8*32WW 100001– 100001– 100001– 100001– 100001– 100001– 100001– 100001– 100001– 100001– 100001–

European specs.

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

General specs. (R.H.D.)
MM6 UNY02100 MM6 UNYOW100

RELATED MATERIALS
B Series Training Manual .......................................... 3333-10-99A Engine Workshop Manual WL, WL Turbo ................ 1532-10-96C Engine Workshop Manual G6 .................................... 1640-10-99A Engine Workshop Manual F2 .................................... 1641-10-99A Manual Transmission Workshop Manual
M15M-D M15MX-D .............................................................. 1645-10-99A

Manual Transmission Workshop Manual R15M-D R15MX-D.................................................... 1642-10-99A B Series Wiring Diagrams (European, General specs. (L.H.D.)) ..................... 5449-10-99A B Series Wiring Diagrams (European, General specs. (R.H.D.)) .................... 5450-10-99A

CONTINUED

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GENERAL INFORMATION
HOW TO USE THIS MANUAL . . . . . . . . . . . . . . . RANGE OF TOPICS . . . . . . . . . . . . . . . . . . . . . SERVICING PROCEDURE . . . . . . . . . . . . . . . SYMBOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ADVISORY MESSAGES . . . . . . . . . . . . . . . . . . TROUBLESHOOTING PROCEDURE . . . . . . TEXT SEQUENCE . . . . . . . . . . . . . . . . . . . . . . . UNITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FUNDAMENTAL PROCEDURES . . . . . . . . . . . . PROTECTION OF THE VEHICLE . . . . . . . . . . PREPARATION OF TOOLS AND MEASURING EQUIPMENT . . . . . . . . . . . . . . SPECIAL SERVICE TOOLS . . . . . . . . . . . . . . . DISCONNECTION OF THE NEGATIVE BATTERY CABLE . . . . . . . . . . . . . . . . . . . . . . REMOVAL OF PARTS . . . . . . . . . . . . . . . . . . . . DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . INSPECTION DURING REMOVAL, DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . ARRANGEMENT OF PARTS . . . . . . . . . . . . . . CLEANING OF PARTS . . . . . . . . . . . . . . . . . . . REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . RUBBER PARTS AND TUBING . . . . . . . . . . . HOSE CLAMPS . . . . . . . . . . . . . . . . . . . . . . . . . TORQUE FORMULAS . . . . . . . . . . . . . . . . . . . . VISE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . GI-1 GI-1 GI-1/2 GI-3 GI-3 GI-3/6 GI-6 GI-7 GI-8 GI-8 GI-8 GI-8 GI-8 GI-8 GI-8 GI-8 GI-8/9 GI-9 GI-9 GI-9 GI–1 9 GI–1 9 GI–10 GI–10 DYNAMOMETER . . . . . . . . . . . . . . . . . . . . . . . . GI–10 INSTALLATION OF RADIO SYSTEM . . . . . . . . GI–10 ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . GI–11 ELECTRICAL PARTS . . . . . . . . . . . . . . . . . . . . GI–11 CONNECTORS . . . . . . . . . . . . . . . . . . . . . . . . . . GI–11/13 ELECTRICAL TROUBLESHOOTING TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . GI–13 JACKING POSITIONS . . . . . . . . . . . . . . . . . . . . . . GI–14 VEHICLE LIFT (2 SUPPORTS) POSITIONS . . . GI–14 SAFETY STAND POSITIONS . . . . . . . . . . . . . . . GI–14 TOWING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . GI–15 TOWING HOOKS . . . . . . . . . . . . . . . . . . . . . . . . GI–16 TIEDOWN HOOKS . . . . . . . . . . . . . . . . . . . . . . . GI–16 IDENTIFICATION NUMBER LOCATIONS . . . . . GI–16 VEHICLE IDENTIFICATION NUMBER . . . . . . GI–16 ENGINE IDENTIFICATION NUMBER . . . . . . . GI–16 NEW STANDARDS . . . . . . . . . . . . . . . . . . . . . . . . GI–17/19 ABBREVIATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . GI–19 PRE-DELIVERY INSPECTION. . . . . . . . . . . . . .GI-20 PRE-DELIVERY INSPECTION TABLE . . . . . . GI-20

HOW TO USE THIS MANUAL
RANGE OF TOPICS D This manual contains the procedures for performing all of the required service operations. The procedures are divided into the following five basic operations. (1) Removal/Installation (2) Disassembly/Assembly (3) Replacement (4) Inspection (5) Adjustment D Simple operations which can be performed easily just by looking at the vehicle, such as removal/installation of parts, jacking, vehicle lift, cleaning of parts, and visual inspection, have been omitted.

SERVICING PROCEDURE Inspection, Adjustment D The procedures for inspections and adjustments are divided into steps. Important points in regard to the location and contents of the procedures are explained in detail and are shown in the illustrations.

SHOWS PROCEDURE ORDER FOR SERVICE

SHOWS TIGHTENING TORQUE SPECIFICATIONS

CONTINUED

GI–1

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HOW TO USE THIS MANUAL
Repair procedure 1. Most repair operations begin with an overview illustration. It identifies the components, shows how the parts fit together, and describes visual part inspection. However, only the removal/installation procedures which need to be performed methodically have written instructions. 2. Expendable parts, tightening torques, and symbols for oil, grease, and sealant are shown in the overview illustration. In addition, symbols indicating parts which require the use of special service tools for removal/installation are also shown. 3. The procedures are numbered and the part that is the main point of that procedure is shown in the illustration with the corresponding number. Occasionally, there are important points or information concerning a procedure. Refer to this information when servicing the related part.
Procedure SHOWS SERVICE ITEM (S) Indicates any relevant references which need to be followed during installation.

“Removal/Installation” Portion “Inspection After Installation” Portion SHOWS PROCEDURE ORDER FOR SERVICE Install the parts by performing Steps 1—3 in reverse order SHOWS SPECIAL SERVICE TOOL (SST) FOR SERVICE OPERATION SHOWS APPLICATION POINTS OF GREASE, ETC. SHOWS TIGHTENING TORQUE SPECIFICATIONS

SHOWS EXPENDABLE PARTS

SHOWS DETAILS SHOWS TIGHTENING TORQUE UNITS

SHOWS THERE ARE REFERRAL NOTES FOR SERVICE

SHOWS SPECIAL SERVICE TOOL (SST) NO.

SHOWS REFERRAL NOTES FOR SERVICE

CONTINUED

GI–2

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HOW TO USE THIS MANUAL
SYMBOLS D There are eight symbols indicating oil, grease, sealant, and the use of SSTs. These symbols show the points of applying or using such materials during service.
Symbol Meaning Apply oil Kind
SECTION F ONLY

TROUBLESHOOTING PROCEDURE Basic Flow of Troubleshooting

Appropriate new engine oil or gear oil Appropriate new brake fluid Appropriate new automatic transaxle/ transmission fluid Appropriate grease Appropriate sealant Appropriate petroleum jelly O-ring, gasket, etc.

ACTUAL TROUBLESHOOTING PROCEDURES SECTION K ONLY

Apply brake fluid Apply automatic transaxle/ transmission fluid Apply grease

IF MENTIONED

Apply sealant

SECTION F ONLY

Apply petroleum jelly

R

Replace part

SST

Use SST

Appropriate SST

On-board diagnosis D The service codes are important hints for repairing malfunctions that are difficult to simulate. By following the service code, perform the inspection to quickly and accurately diagnose the malfunction. D The self-diagnostic function is used during inspection. When a service code is shown, specifying the cause of a malfunction, continue the inspection according to the items indicated by the self-diagnostic function. Engine tune-up (Section F) D Any necessary adjustments are made after starting the engine. Basic inspection (Section K) D The basic inspection is performed to quickly narrow down the possible causes after a malfunction occurs regardless of the symptoms. ST The basic inspection is performed to also locate the region of many malfunction symptoms. Diagnostic index D The diagnostic index lists the symptoms of the malfunctions. Select the symptoms pertaining or most closely pertaining to the actual malfunction. Quick diagnosis chart (If mentioned) D The quick diagnosis chart lists the diagnosis and inspection procedures to be performed specifically relating to the cause of the malfunction. Symptom troubleshooting D Symptom troubleshooting quickly determines the location of the malfunction according to the type of symptoms.

ADVISORY MESSAGES You’ll find several Warnings, Cautions, Notes, Specifications and Upper and lower limits in this manual. Warning D A Warning indicates a situation in which serious injury or death could result if the warning is ignored. Caution D A Caution indicates a situation in which damage to the vehicle could result if the caution is ignored. Note D A Note provides added information that will help you to complete a particular procedure. Specification D The values indicate the allowable range when performing inspections or adjustments. Upper and lower limits D The values indicate the upper and lower limits that must not be exceeded when performing inspections or adjustments.

CONTINUED

GI–3

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HOW TO USE THIS MANUAL
Procedures For Use Using the basic inspection
D D D D

Perform the basic inspection before the symptom troubleshooting. Perform each step in the order shown. The reference column lists the location of the detailed procedure for each basic inspection. Although inspection and adjustment are performed as according to the procedures referred to in the reference column, if the cause of the malfunction is discovered during the basic inspection, continue the procedures as indicated in the remarks column.
SHOWS INSPECTION ORDER SHOWS ITEM NAMES FOR THE DETAILED PROCEDURES

SHOW POINTS REQUIRING ATTENTION IN REGARD TO INSPECTION RESULTS

Perform malfunction diagnosis according to No. 26 “HOLD INDICATOR LIGHT DOES NOT ILLUMINATE WHEN HOLD SWITCH IS TURNED ON” or No. 27 “HOLD INDICATOR LIGHT ILLUMINATES WHEN HOLD SWITCH IS NOT TURNED ON”

Using the diagnostic index D The symptoms of the malfunctions are listed in the diagnostic index for system troubleshooting. D The exact malfunction symptoms can be selected using the details.

CONTINUED

GI–4

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HOW TO USE THIS MANUAL
Using the quick diagnosis chart D The chart lists the relation between the symptoms and cause of the malfunction. D The chart is effective in quickly narrowing down the relation between the symptoms and cause of the malfunction and specifying the region of the common cause when multiple malfunction symptoms occur. D The appropriate diagnostic inspection relating to the cause of the malfunction as specified by the symptoms can be selected by looking down the diagnostic inspection column of the chart.

PARTS WHICH MAY BE THE CAUSE OF PROBLEMS
ENGINE QUICK DIAGNOSTIC CHART

PART WHICH MAY BE THE SYMPTOM

CHOOSE THE ACTUAL SYMPTOM

ST

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GI–5

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HOW TO USE THIS MANUAL
Using the symptom troubleshooting
D Symptom troubleshooting shows diagnosis procedure, inspection method, and proper action to take for each

trouble symptom.

TROUBLESHOOTING HINTS describes possible point of malfunction.

TROUBLE SYMPTOM

STEP shows the order of troubleshooting. INSPECTION describes an inspection (method) to quickly determine the failed part.

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

Reference page(s) for the detailed procedure to perform INSPECTION is shown. How to perform ACTION is described in the relative material shown.

TEXT SEQUENCE D The text sequence is as indicated by the arrows shown below. Example:

CONTINUED

GI–6

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UNITS

UNITS
Electric current Electric power Electric resistance Electric voltage Length A (ampere) W (watt) W (ohm) V (volt) mm (millimeter) in (inch) kPa (kilo pascal) Negative pressure mmHg (millimeters of mercury) inHg (inches of mercury) kPa (kilo pascal) Positive pressure kgf/cm2 (kilogram force per square centimeter) psi (pounds per square inch) Number of revolutions rpm (revolutions per minute) N·m (Newton meter) kgf·m (kilogram force per meter) Torque kgf·cm (kilogram force per 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) Weight g (gram) oz (ounce)

D The actual converted values for 2.7 kgf/cm2 are

264 kPa and 38.4 psi. In the top specification, 2.7 is used as an upper limit, so its converted values are rounded down to 260 and 38. In the bottom specification, 2.7 is used as a lower limit, so its converted values are rounded up to 270 and 39.

Conversion to SI Units (Système International d’Unités) D All numerical values in this manual are based on SI units. Numbers shown in conventional units are converted from these values. Rounding off D Converted values are rounded off to the same number of places as the SI unit value. For example, if the SI unit value is 17.2 and the value after conversion is 37.84, the converted value will be rounded off to 37.8. Upper and lower limits D When the data indicates upper and lower limits, the converted values are rounded down if the SI unit value is an upper limit and rounded up if the SI unit value is a lower limit. Therefore, converted values for the same SI unit value may differ after conversion. For example, consider 2.7 kgf/cm2 in the following specifications: 210—260 kPa {2.1—2.7 kgf/cm2, 30—38 psi} 270—310 kPa {2.7—3.2 kgf/cm2, 39—45 psi}

ST

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GI–7

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FUNDAMENTAL PROCEDURES

FUNDAMENTAL PROCEDURES
PROTECTION OF THE VEHICLE D Always be sure to cover fenders, seats, and floor areas before starting work.

REMOVAL OF PARTS D While correcting a problem, try also to determine its cause. Begin work only after first learning which parts and subassemblies must be removed and disassembled for replacement or repair. After removing the part, plug all holes and ports to prevent foreign material from entering.

PREPARATION OF TOOLS AND MEASURING EQUIPMENT D Be sure that all necessary tools and measuring equipment are available before starting any work.

DISASSEMBLY D If the disassembly procedure is complex, requiring many parts to be disassembled, all parts should be marked in a place that will not affect their performance or external appearance and identified so that reassembly can be performed easily and efficiently.

SPECIAL SERVICE TOOLS D Use special tools when they are required.

INSPECTION DURING REMOVAL, DISASSEMBLY D When removed, each part should be carefully inspected for malfunctioning, deformation, damage, and other problems.

DISCONNECTION OF THE NEGATIVE BATTERY CABLE D Before beginning any work, turn the ignition switch to LOCK, then disconnect the negative battery cable and wait for more than 1 minute to allow the backup power supply of the SAS unit to deplete its stored power. Disconnecting the battery cable will delete the memories of the clock, audio, and DTCs, etc. Therefore, it is neccessary to verify those memories before disconnecting the cable.

ARRANGEMENT OF PARTS D All disassembled parts should be carefully arranged for reassembly. D Be sure to separate or otherwise identify the parts to be replaced from those that will be reused.

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GI–8

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FUNDAMENTAL PROCEDURES
D Oil should be applied to the moving components of

parts.
D Specified oil or grease should be applied at the

prescribed locations (such as oil seals) before reassembly.

CLEANING OF PARTS D All parts to be reused should be carefully and thoroughly cleaned using the appropriate method. Warning D Using compressed air can cause dirt and other particles to fly out, causing injury to the eyes. Wear protective eye wear whenever using compressed air.
SXU00012

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

SXU00013

REASSEMBLY D Standard values, such as torques and certain adjustments, must be strictly observed in the reassembly of all parts. If removed, these parts should be replaced with new ones:
1 3 5 Oil seals O-rings Cotter pins 2 4 6 Gaskets Lockwashers Nylon nuts

RUBBER PARTS AND TUBING D Prevent gasoline or oil from spilling on rubber parts or tubing.

ST
SXU00014

HOSE CLAMPS D When reinstalling, position the hose clamp in the original location on the hose, and squeeze the clamp lightly with large pliers to ensure a good fit.

SXU00011

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

specified locations. When sealant is applied, parts should be installed before sealant hardens. Hardened sealant causes leaks.

CONTINUED

SXU00015

GI–9

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FUNDAMENTAL PROCEDURES, INSTALLATION OF RADIO SYSTEM
TORQUE FORMULAS D When using a torque wrench-SST combination, the written torque must be recalculated due to the extra length that the SST adds to the torque wrench. Recalculate the torque using the following formulas. Choose the formula that applies to you.
Torque Unit kgf·m kgf·cm ft·lbf in·lbf Formula kgf·m kgf·cm ft·lbf in·lbf [L/(L+A) ] [L/(L+A) ] [L/(L+A) ] [L/(L+A) ]

INSTALLATION OF RADIO SYSTEM
If a radio system is installed improprerly or if a highpowered type is used, the CIS and other systems may be affected. When the vehicle is to be equipped with a radio, observe the following precautions. 1. Install the antenna at the farthest point from control modules. 2. Install the antenna feeder as far as possible from the control modules harness, and perpendicular to wiring harnesses. 3. Do not install a high-powered radio system. 4. After installing the radio system, start and idle the engine, then confirm that the engine is not influenced by output waves from the system.

A: The length of the SST past the torque wrench drive. L: The length of the torque wrench.

SXU00016

VISE D When using a vise, put protective plates in the jaws of the vise to prevent damage to parts.

SXU00017

DYNAMOMETER When test-running a vehicle on dynamometer : D Place a fan, preferably a vehicle-speed proportional type, in front of the vehicle. D Connect an exhaust gas ventilation unit. D Cool the exhaust pipes with a fan. D Keep the area around the vehicle uncluttered. D Watch the water temperature gauge.

CONTINUED

GI–10

Check the terminals of waterproof connectors from the connector side. FROM. CONNECTORS Data Link Connector D Insert the probe into the service hole when connecting a jumper wire to the data link connector.REPAIR MANUAL PAGES. grasp the connectors. disconnect the negative battery cable. SXU00019 SXU00023 2.CHAPTER. CONTINUED GI–11 . Caution D Inserting a jumper wire probe into the data link connector terminal may damage the terminal. insert the tester probe from the wiring harness side.BACK.INDEX ELECTRICAL SYSTEM ELECTRICAL SYSTEM ELECTRICAL PARTS Battery Cable D Before disconnecting connectors or removing electrical parts. SXU00022 Inspection 1.DRFT. pry up the hook of the clip using a flathead screwdriver. listen for a click that will indicate they are securely locked. SXU00021 Locking Connector D When locking connectors. as they cannot be accessed from the wiring harness side.INDEX RANG. When a tester is used to check for continuity or to measure voltage. MODEL . not the wires. SXU00020 D Connectors can be disconnected by pressing or pulling the lock lever as shown. Disconnecting Connectors D When disconnecting two connectors.TO. SXU00018 Wiring Harness D To remove the wiring harness from the clip in the engine room. MANUAL TO.

SXU00026 Sensors. MODEL . SXU00027 SXU00024 Terminals Inspection D Pull lightly on individual wires to check that they are secured in the terminal. Be sure the negative battery terminal is disconnected before replacing a main fuse. D The first letter indicates the base color of the wire and the second the color of the stripe.BACK. CONTINUED SXU00029 GI–12 . D Insert a thin piece of metal from the terminal side of the connector. TYPE A TYPE B RED YELLOW SXU00028 Fuse Replacement 1. Do not drop them or strike them against other objects. Wiring Harness Wiring color codes D Two-color wires are indicated by a two-color code symbol. and Relays D Handle sensors. CODE B BR G GY L LB LG B/R COLOR Black Brown Green Gray Blue Light Blue Light Green CODE O P R V W Y COLOR Orange Pink Red Violet White Yellow BR/Y BLACK BROWN SXU00025 Replacement D Use the appropriate tools to remove a terminal as shown. When replacing a fuse. and relays carefully.REPAIR MANUAL PAGES. If a fuse again fails after it has been replaced. Switches.INDEX ELECTRICAL SYSTEM Caution D To prevent damage to the terminal.TO. When installing a terminal.DRFT.CHAPTER. with the terminal locking tab pressed down. and then. pull the terminal out from the connector. be sure to insert it until it locks securely. 2. wrap a thin wire around the lead before inserting it into the terminal. the circuit probably has a short and the wiring should be checked. be sure to replace it with one of the specified capacity. switches. MANUAL TO. FROM.INDEX RANG.

DRFT. use the fuse puller. this may cause burning or other damage to wiring harnesses or electronic components. MODEL .INDEX RANG. PULLER Ohmmeter D The ohmmeter is used to measure the resistance between two points in a circuit.CHAPTER.REPAIR MANUAL PAGES. OHMMETER GROUND LINE SXU00034 SXU00032 Voltmeter D The DC voltmeter is used to measure circuit voltage. and to check for continuity and short circuits.BACK. This will damage the ohmmeter. FROM.INDEX ELECTRICAL SYSTEM 3. POWER SOURCE LINE FUSE SXU00030 ELECTRICAL TROUBLESHOOTING TOOLS Jumper Wire D A jumper wire is used to create a temporary circuit. Caution D Do not connect the ohmmeter to any circuit to which voltage is applied. MANUAL TO.TO. When replacing a pullout fuse. Caution D Do not connect a jumper wire from the power source line to a body ground. Connect the jumper wire between the terminals of a circuit to bypass a switch. VOLTMETER POWER SOURCE LINE BLACK LEAD RED LEAD GROUND CONTINUED GI–13 . A voltmeter with a range of 15 V or more is used by connecting the positive (+) probe (red lead wire) to the point where voltage is to be measured and the negative (–) probe (black lead wire) to a body ground.

INDEX JACKING POSITIONS. VEHICLE LIFT (2 SUPPORTS) POSITIONS. Use only the correct front and rear jacking positions and block the wheels.DRFT. Use safety stands to support the vehicle after it has been lifted. SAFETY STAND POSITIONS JACKING POSITIONS Warning D Improperly jacking a vehicle is dangerous. FROM. FRONT REAR SAFETY STAND POSITIONS FRONT REAR REAR VEHICLE LIFT (2 SUPPORTS) POSITIONS FRONT CONTINUED GI–14 . MANUAL TO.TO.CHAPTER. MODEL . The vehicle can slip off the jack and cause serious injury.BACK.REPAIR MANUAL PAGES.INDEX RANG.

(With Automatic Transmission) If excessive damage or other conditions prevent towing the vehicle with the driving wheels off the ground. MANUAL TO.INDEX RANG. Set the transfer case at 2H and the hubs at FREE.TO. Government and local laws must be followed. MODEL . If your Ford/Mazda has 4 4. rear axle. change to 2-wheel drive before having the vehicle towed. the vehicle may be towed only forward. the vehicle may be towed on all four wheels. tow with the rear wheels off the ground. and steering will not be available when the engine is not running. Turn the engine switch to ACC position. Release the parking brake. 2. If speed must exceed 45 km/h (28 mph) or a towing distance of 15 km (9.REPAIR MANUAL PAGES. D Remember that power assist for the brakes Caution D Do not tow with sling-type equipment. (All Models) 1. use one of these methods: D Place the rear wheels on dollies. Wheel dollies D Disconnect the propeller shaft. Use wheel-lift or flatbed equipment. If the transmission or rear axle is inoperative. 2. Caution D Follow these instructions when towing the vehicle with all wheels on the ground or with the front wheels on the ground and the rear wheels raised. Do not exceed 45 km/h (28 mph) and a distance of 15 km (9. D Tow with the rear wheels off the ground. If any of these components are damaged.CHAPTER.INDEX TOWING TOWING Proper lifting and towing are necessary to prevent damage to the vehicle. If this is not possible. Wheel dollies If all four wheels are on the ground.3 miles). you could damage the transmission. FROM. (With Manual Transmission) If the transmission.3 miles). Set the transmission in neutral.DRFT. and steering system are not damaged. This could damage your vehicle.BACK. use wheel dollies. 3. tow with all four wheels raised. (4 4 Model) 1. CONTINUED GI–15 . use wheel dollies. Put the transfer case in 2H.

g. IDENTIFICATION NUMBER LOCATIONS TOWING HOOKS Caution D The towing hooks should be used only in an emergency (e. Apply no sideways force. always pull the cable or chain in a straight direction with respect to the hook.REPAIR MANUAL PAGES.INDEX TOWING. MANUAL TO.CHAPTER.DRFT.BACK. D When using the towing hooks. FRONT 4 4 IDENTIFICATION NUMBER LOCATIONS VEHICLE IDENTIFICATION NUMBER ENGINE IDENTIFICATION NUMBER G6 TIEDOWN HOOKS Caution D Do not use the hook loops under the front for towing. FRONT 4 2 WL.TO. MODEL . FROM. They are designed ONLY for tying down the vehicle when it is being transported. Using them for towing will damage the bumper. to get the vehicle out of a ditch or a snow bank).INDEX RANG. WL Turbo F2 CIS F2 CARB 4 4 CONTINUED GI–16 .

That relay is now called the fuel pump relay (speed).BACK.INDEX NEW STANDARDS NEW STANDARDS D Following is a comparison of the previous standard and the new standard. #6: Part name of diesel engine CONTINUED GI–17 .CHAPTER.INDEX RANG. FROM. MANUAL TO.REPAIR MANUAL PAGES. New Standard Abbreviation AP ACL A/C BARO B) — — CMP sensor CAC CLS CTP — CPP CIS CS sensor CKP sensor DLC DTM DTC DI DLI EI ECT EM — EVAP EGR FC FF 4GR — FSO solenoid GEN GND HO2S IAC — Name Accelerator Pedal Air Cleaner Air Conditioning Barometric Pressure Battery Positive Voltage Brake Switch Calibration Resistor Camshaft Position Sensor Charge Air Cooler Closed Loop System Closed Throttle Position Closed Throttle Position Switch Clutch Pedal Position Continuous Fuel Injection System Control Sleeve Sensor Crankshaft Position Sensor Data Link Connector Diagnostic Test Mode Diagnostic Trouble Code(s) Distributor Ignition Distributorless Ignition Electronic Ignition Engine Coolant Temperature Engine Modification Engine Speed Input Signal Evaporative Emission Exhaust Gas Recirculation Fan Control Flexible Fuel Fourth Gear Fuel Pump Relay Fuel Shut Off Solenoid Generator Ground Heated Oxygen Sensor Idle Air Control Incorrect Gear Ratio Abbreviation — — — — VB — — — — — — — — EGI CSP sensor — — — — — — — — — — — — — — — — FCV — — — — — Previous Standard Name Accelerator Pedal Air Cleaner Air Conditioning Atmospheric Pressure Battery Voltage Stoplight Switch Corrected Resistance Crank Angle Sensor Intercooler Feedback System Fully Closed Idle Switch Clutch Position Electronic Gasoline Injection System Control Sleeve Position Sensor Crank Angle Sensor 2 Diagnosis Connector Test Mode Service Code(s) Spark Ignition Direct Ignition Electronic Spark Ignition Water Thermo Engine Modification Engine RPM Signal Evaporative Emission Exhaust Gas Recirculation Fan Control Flexible Fuel Overdrive Circuit Opening Relay Fuel Cut Valve Alternator Ground/Earth Oxygen Sensor Idle Speed Control — With heater #3 #6 #2 #1 #6 #6 Remark #1: Diagnostic trouble codes depend on the diagnostic test mode #2: Controlled by the PCM #3: In some models.DRFT. there is a fuel pump relay that controls pump speed. MODEL .TO.

CHAPTER. FROM. MODEL .REPAIR MANUAL PAGES.DRFT.INDEX NEW STANDARDS New Standard Abbreviation — — IAT KS MIL MAP MAF sensor MFL OBD OL — OC O2S PNP — PSP PCM — PAIR — AIR SAPV SFI — — — 3GR TWC TB TP sensor TCV TCC TCM — TR TC VSS VR Injection Pump Input/Turbine Speed Sensor Intake Air Temperature Knock Sensor Malfunction Indicator Lamp Manifold Absolute Pressure Mass Air Flow Sensor Multiport Fuel Injection On-Board Diagnostic Open Loop Output Speed Sensor Oxidation Catalytic Converter Oxygen Sensor Park/Neutral Position PCM Control Relay Power Steering Pressure Powertrain Control Module Pressure Control Solenoid Pulsed Secondary Air Injection Pump Speed Sensor Secondary Air Injection Secondary Air Pulse Valve Sequential Multipoint Fuel Injection Shift Solenoid A Shift Solenoid B Shift Solenoid C Third Gear Three Way Catalytic Converter Throttle Body Throttle Position Sensor Timer Control Valve Torque Converter Clutch Transmission (Transaxle) Control Module Transmission (Transaxle) Fluid Temperature Sensor Transmission (Transaxle) Range Turbocharger Vehicle Speed Sensor Voltage Regulator Name Abbreviation FIP — — — — — — — — — — — — — — — ECU — — — — — — — — — — — — — — — TCV — — — — — — — Previous Standard Name Fuel Injection Pump Pulse Generator Intake Air Thermo Knock Sensor Malfunction Indicator Light Intake Air Pressure Airflow Sensor Multiport Fuel Injection Diagnosis/Self-Diagnosis Open Loop Vehicle Speed Sensor 1 Catalytic Converter Oxygen Sensor Park/Neutral Range Main Relay Power Steering Pressure Engine Control Unit Line Pressure Solenoid Valve Secondary Air Injection System NE Sensor Secondary Air Injection System Reed Valve Sequential Fuel Injection 1–2 Shift Solenoid Valve Shift A Solenoid Valve 2–3 Shift Solenoid Valve Shift B Solenoid Valve 3–4 Shift Solenoid Valve 3rd Gear Catalytic Converter Throttle Body Throttle Sensor Timing Control Valve Lock-up Position EC-AT Control Unit ATF Thermosensor Inhibitor Position Turbocharger Vehicle Speed Sensor IC Regulator #6 Pulsed injection #6 Injection with air pump #4 #6 #6 Remark #4: Device that controls engine and powertrain #6: Part name of diesel engine CONTINUED GI–18 . MANUAL TO.TO.INDEX RANG.BACK.

. . . . . . MFW . . . . .. . . . . . . ... .. . . . . . . . . . . .. .. . . . . . ATF . . . . ATDC . . . . . . . . . .. . RH . SAS . . . . . . . EX . . . . . . . . . . . . . . . . . . . ... . IN . . 4 2 . P/S . . . .BACK. . . . . . . . . . 4WD . . BTDC . . . . . . . .. . .. . . . . . . . . . . . . . .. . . . . . . .. . . . . MANUAL TO. . . .INDEX NEW STANDARDS. . Accessories After top dead center Automatic transmission fluid Before top dead center Carburetor Emergency locking retractor Exhaust Fuel injection pump High Hydraulic lash adjuster Ignition Intake Intermittent Left hand Left hand drive Low Limited slip differential Load sensing proportioning valve Motor Maximum Manual freewheel Minimum Power steering Remote freewheel Right hand Right hand drive Sophisticated air bag sensor Special service tool Tail number side lights 2 wheel drive 4 wheel drive 4 wheel – 2 drive 4 wheel – 4 drive CONTINUED GI–19 . . . . . RFW . . MAX . .. CARB . . . . . . .. . . . . . . . . . . . . . . . LH . . .. . . . MIN . . . . . . . . . .TO. .. .H. . . ...CHAPTER. . . . . .. . .. . . . . . . . . . . . . . HLA . . . . . . . . .. . . . . . . . . R. . INT . . . . . .. . . .. . . . . .. . .H. . . . . ELR . L. . . . . . . MODEL . . . LSD . .. . . . . . . LO . . . . . .. . FROM. . .. .INDEX RANG.REPAIR MANUAL PAGES. . . .. . .D. . . . . . . . . . .. . TNS . . . . . . . LSPV . . . . 4 4 .. M . . .DRFT. . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . IG . . . . . . . . . . . . . . . . ... . . . . . . . . . . . . . . SST .. . . . . . . . . . . . .. . 2WD . . . . . .. . . . . . . . . FIP . .. . . . HI . . . . . . . . . . . . . .. . .. ABBREVIATIONS New Standard Abbreviation VAF sensor WU-TWC WOT Name Volume Air Flow Sensor Warm Up Three Way Catalytic Converter Wide Open Throttle Abbreviation — — — Previous Standard Name Air flow Sensor Catalytic Converter Fully Open #5 Remark #5: Directly connected to exhaust manifold ABBREVIATIONS ACC .. . . . . . . . . . . .D. . . .

fittings. exhaust system and all underside hardware for looseness or damage ROAD TEST CHECK the following items: Brake operation Clutch operation Steering control Operation of meters and gauges 3 Squeaks. suspension. electrolyte level and specific gravity Drive belt tensions Accelerator cable and linkage for free movement CLEAN the spark plugs INTERIOR INSTALL the following parts Fuse for accessories CHECK the operation of the following items: Seat controls (sliding and reclining) and headrest Door locks Ignition switch (Engine switch) and steering lock All lights including warning and indicator lights Horn. the following items: Operation and fit of windows Pedal height and free play of brake and clutch pedals Parking brake UNDER BONNET-ENGINE RUNNING AT OPERATING TEMPERATURE CHECK the following items: Operation of dashpot Initial ignition timing Injection timing Idle speed Operation of throttle position sensor ON HOIST CHECK the following items: Operation of freewheel hubs Manual transmission oil level Transfer oil level Front differential oil level Rear differential oil level Underside fuel. the following items to the specifications: Glass. FROM. connections and components for leaks Engine oil level Power steering fluid level (if equipped) Brake and clutch master cylinder fluid levels Windshield washer reservoir fluid level Radiator coolant and specific gravity Tightness of water hose clamps Tightness of battery terminals. windshield wipers and washers (if equipped) Wiper blades performance Clean the wiper blades and windshield Antenna Cigarette lighter and clock Tilt steering (if equipped) Air conditioner at various modes (if equipped) CHECK the following items: Presence of spare fuse Upholstery and interior finish CHECK and ADJUST . fittings.INDEX RANG. MANUAL TO. rattles or unusual noise Engine general performance Emergency locking retractors Operation of transfer AFTER ROAD TEST REMOVE seat and floor mat protective covers CHECK for necessary owner's information material.INDEX PRE-DELIVERY INSPECTION PRE-DELIVERY INSPECTION PRE-DELIVERY INSPECTION TABLE Following items may be done at any time prior to delivery to your customer.BACK. MODEL . tools and spare tire in vehicle CONTINUED Gl-20 .DRFT.TO. EXTERIOR INSPECT and ADJUST.REPAIR MANUAL PAGES.CHAPTER. if necessary. if necessary. exterior bright metal and paint for damage Wheel lug nuts Tire pressures All weatherstrips for damage or detachment Operation of bonnet release and lock Door operation and alignment Headlight aiming INSTALL the following parts: Wheel caps UNDER BONNET-ENGINE OFF INSPECT and ADJUST . connections and components for leaks Tires for cuts or bruises Steering linkage. coolant and hydraulic lines. coolant and hydraulic lines. if necessary. the following items to the specifications: Fuel.

.............2—8.......... (Refer to DRIVE BELT........ or at least 30 minutes after the engine has been stopped............55} 7.47} 6................. MODEL ..... 22 Ibf} midway between the specified pulleys........... B1-3/5 CYLINDER HEAD GASKET ..............28} 8.B1-6/9 HYDRAULIC LASH ADJUSTER (HLA).48—0.....DRFT........ Using the SST.......MAIN........ MANUAL TO.....0 {0........B1-13 REAR OIL SEAL ..B1-13 FRONT OIL SEAL REPLACEMENT ...4.....B1-6 CYLINDER HEAD GASKET REPLACEMENT ........... Ibf} Drive belt Generator P/S *New 491-588 {50-60. Belt tension can be checked in place of belt deflection...........B1-14 ENGINE ....B1-15 ENGINE REMOVAL/INSTALLATION ...................31} 10......0—56..........B1-2 COMPRESSION INSPECTION ...5 {0..................REPAIR MANUAL PAGES....INDEX ENGINE (G6) DRIVE BELT .40—0.B1-2 TIMING CHAIN .... Check the drive belt deflection when the engine is cold.................0—12..................TO..................26—0............ Apply pressure 98 N {10 kgf........................ If the deflection is not within the specification..............INDEX RANG.......5—10................) Drive Belt Tension Check 1.. 125—143} Used 393-490 {40-50......93—105} 557—641 {56.........................0 {0.........88-110} 354—402 {36-41..... CONTINUED B1-1 ............. or at least 30 minutes after the engine has been stopped..... 80—90} 471—556 {48........2 {0...........0—11..29—0..........0 {0....39} Used mm {in} 12.....34—0....7—65. FROM.......B1-14 REAR OIL SEAL REPLACEMENT ... check the belt tension between any two pulleys.........................B1-1 DRIVE BELT INSPECTION ...........................7...BACK.0 {0......40—0....................110-132} 412—470 {42-48..B1-10 DRIVE BELT DRIVE BELT INSPECTION Drive Belt Deflection Check 1..... 106—124} A/C * A belt that has been on a running engine for less than five minutes....0—14........ N {kgf...45} *: A belt that has been on a running engine for less than five minutes................ Check the drive belt tension when the engine is cold....6—7.......B1-12 FRONT OIL SEAL....B1-3 TIMING CHAIN REMOVAL/ INSTALLATION ..........B1-10/11 HLA TROUBLESHOOTING ....................B1-17 Deflection Drive belt Generator P/S A/C *New 10..B1-1/2 DRIVE BELT ADJUSTMENT ........ DRIVE BELT ADJUSTMENT.. HLA REMOVAL/INSTALLATION .. 2... adjust it................................................................B1-15/16 ENGINE DISASSEMBLY/ASSEMBLY ..

IGNITION COIL REMOVAL/INSTALLATION. 8. FROM.DRFT. or cylinder wall may be worn and overhaul is required. (Refer to section F1. MANUAL TO. Adjust the belt deflection or tension by turning the adjusting bolt D. Disconnect the compression gauge. (Refer to DRIVE BELT.0.1 spark plug hole. pour a small amount of clean engine oil into the cylinder and recheck the compression.INDEX RANG. Battery. CONTINUED B1-2 . Verify that the battery is fully charged. DRIVE BELT ADJUSTMENT. 12. (1) If the compression increases. 28 psi} 11. 182} [270] 882. If the compression in one or more cylinders is low or the compression difference between cylinders exceeds the maximum. 128} [270] 196 kPa {2.) 3. (2) If the compression stays low. 3.5—2. If the tension is not within the specification.) 5. (Refer to section G.m {1. (3) If the compression in adjacent cylinders stays low.lbf} 14.CHAPTER. Recharge it if necessary. adjust it. Leave the fuel pump relay removed. Install the fuel pump relay. they can badly burn. Connect the igniter connector.INDEX DRIVE BELT.) 2. 1.REPAIR MANUAL PAGES.) DRIVE BELT ADJUSTMENT 1. Fully depress the accelerator pedal and crank the engine. the piston rings. Disconnect the igniter connector.TO.m.6 {9. the cylinder head gasket may be damaged or the cylinder head distorted and overhaul is required. BATTERY INSPECTION. BEFORE REPAIR PROCEDURE. Tightening torque 15—22 N. psi} [rpm] Engine type G6 1255 {12. Loosen mounting bolts A and B. 4. COMPRESSION INSPECTION 2. FUEL SYSTEM. Install the spark plugs. 15. MODEL . a valve may be stuck or improperly seated and overhaul is required. 10. Tighten mounting bolts A and B and locknut C.) 6. 2. COMPRESSION INSPECTION Warning • When the engine and the oil are hot.3 kgf. Stop the engine and allow it to cool off for about 10 minutes.0 kgf/cm 2. 7. Warm up the engine to the normal operating temperature. Be careful not to burn yourself during removal/installation of each component. IGNITION SYSTEM. 9. (Refer to section G. (Refer to DRIVE BELT. 13. Perform "Fuel Line Safety Procedure". and locknut C. Remove the spark plugs. CHARGING SYSTEM. DRIVE BELT INSPECTION.8. 11—l6ft. the piston. Connect a compression gauge into the No. Compression Item Standard Minimum Maximum difference between kPa {kgf/cm2. Note the maximum gauge reading. Inspect compression of each cylinder.BACK.

OIL PAN REMOVAL/INSTALLATION. 1 2 3 4 5 6 7 8 9 A/C compressor bracket Generator strap P/S oil pump bracket Generator bracket Pulley lock bolt ☞ Removal/Installation Note Crankshaft pulley Chain cover Spacer Balancer chain guide ☞ Installation Note 10 11 12 13 14 15 Balancer chain. Remove in the order indicated in the table.DRFT. ENGINE SPEED SENSING POWER STEERING. Remove the water pump.INDEX TIMING CHAIN TIMING CHAIN TIMING CHAIN REMOVAL/INSTALLATION 1. crankshaft sprocket ☞ Installation Note Timing chain. Remove the generator. 3. (Refer to section E. Remove the cylinder head. idler sprocket. POWER STEERING OIL PUMP REMOVAL/INSTALLATION. WATER PUMP. (Refer to section D. Remove the A/C compressor with the pipe still connected. 11.REPAIR MANUAL PAGES. timing sprocket.) 7.) 8. Position the A/C compressor so that it is out of the way. OIL PAN.INDEX RANG. 5. MANUAL TO. Install in the reverse order of removal. Remove the oil pan. 10. FROM. WATER PUMP REMOVAL/INSTALLATION. camshaft sprocket ☞ Installation Note Chain adjuster ☞ Installation Note Key Timing chain lever ☞ Installation Note Timing chain guide CONTINUED B1-3 . Disconnect the oil strainer stay. (Refer to section N. (Refer to CYLINDER HEAD GASKET. MODEL . 9.) 4. Disconnect the negative battery cable. 2.TO. Position the P/S oil pump so that it is out of the way.) 6.CHAPTER.BACK. Remove the P/S oil pump with the oil hose still connected. Start the engine and check for engine oil and engine coolant leakage. CYLINDER HEAD GASKET REPLACEMENT.

BACK. 3. Balancer Chain. Install the timing chain and timing sprocket so that the white link of the timing chain is aligned with the timing mark of the timing sprocket as shown. Install the crankshaft sprocket as shown. Assemble the idler sprocket on to the idler shaft.INDEX TIMING CHAIN Pulley Lock Bolt Removal/Installation Note • Hold the crankshaft using the SST . Timing Chain. Camshaft Sprocket Installation Note 1.CHAPTER. Crankshaft Sprocket Installation Note 1. FROM.REPAIR MANUAL PAGES. 3. Assemble the camshaft sprocket to the timing chain so that the timing mark of camshaft sprocket is aligned with the white link of timing chain as shown. 2. Timing Chain Lever Installation Note • Install the chain lever and verify that it moves smoothly in the direction indicated. Timing Sprocket. MANUAL TO.DRFT.INDEX RANG. CONTINUED B1-4 . 2. MODEL .TO. Chain Adjuster Installation Note • Push the chain adjuster sleeve in (toward the left) and insert the pin as shown into the lever to hold the sleeve. Idler Sprocket. Secure the camshaft sprocket and the timing chain with a wire to prevent disengagement. Set the balancer chain on the idler sprocket so that the timing mark of the idler sprocket is aligned with the brown link of the balancer chain as shown.

MODEL .INDEX TIMING CHAIN 4. CONTINUED B1-5 .8 mm {0.13—0. then pull back the chain guide 3.REPAIR MANUAL PAGES. Note • The balancer chain must be replaced if chain guide C bottoms when adjusting. and attach the idler sprocket to the cylinder block.0 kgf. 3. Install the balancer chain so that the five alignment marks on the chain. FROM.12 in} 2. sprocket and cylinder block align. Balancer Chain Guide Installation Note 1.BACK. and tighten the bolt D and hand-tighten the adjusting bolt E. Push the chain guide C with a force of 49 N {5.14 in] and tighten the adjusting bolt E. Specification Approx. Install the chain guide A and B.INDEX 4. Tighten the idler sprocket lock bolt.DRFT. Hand-tighten the idler sprocket lock bolt. 5.CHAPTER. MANUAL TO.TO. Measure the timing chain slack. RANG. Install the chain guide C. 5.0 mm {0. 3. 6. Loosen the chain guide C by adjusting bolt E. 11 Ibf} in the direction of the arrow.2—3.

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

INDEX RANG.CHAPTER.TO.REPAIR MANUAL PAGES. MANUAL TO.BACK. MODEL . FROM.DRFT.INDEX CYLINDER HEAD GASKET 1 2 3 Upper radiator hose Cylinder head cover ☞ Installation Note Distributor drive gear ☞ Removal Note ☞ Installation Note Camshaft sprocket ☞ Removal Note ☞ Installation Note 5 Cylinder head ☞ Removal Note ☞ Installation Note Cylinder head gasket ☞ Installation Note 6 4 CONTINUED B1-7 .

Cylinder Head Removal Note 1. MODEL .INDEX RANG. Remove the seal cover.BACK. 4. 5. Hold the crankshaft using the SST . 2.TO. Remove the service cover on the chain cover. 2.REPAIR MANUAL PAGES.12 in} 2.DRFT.0 mm {0. Cylinder Head Gasket Installation Note • Apply silicone sealant to the areas shown. Verify that the camshaft sprocket mark is aligned with the horizontal surface on the cylinder head. 3. Remove the lock bolt. Remove the bolts A. FROM.1 piston is at TDC of the compression stroke. MANUAL TO. Thickness Ø 3. 4. Secure the camshaft sprocket and the chain with a wire as shown. Camshaft Sprocket Removal Note 1.INDEX CYLINDER HEAD GASKET Distributor Drive Gear Removal Note 1. Push the chain adjuster sleeve in (toward the left) and insert a pin as shown into the lever hole to hold the sleeve. 3. CONTINUED B1-8 .CHAPTER. Turn the crankshaft clockwise so that the No. Remove the camshaft sprocket off the camshaft dowel pin. Loosen the cylinder head bolts a few turns in the order shown.

Install the camshaft sprocket onto the camshaft dowel pin. 2. 3. 2. 3. Apply silicone sealant to the cylinder head as shown. Tighten the cylinder head bolts a few turns in the order shown. 4. and install it onto the cylinder head cover.REPAIR MANUAL PAGES.BACK.cm. CONTINUED B1-9 .lbf} 5. Verify that the grooves on the cylinder head cover are free of oil. Distributor Drive Gear Installation Note 1.9—10. Hold the camshaft with a screwdriver as shown. Camshaft Sprocket Installation Note 1. MODEL . 4.INDEX CYLINDER HEAD GASKET Cylinder Head Installation Note 1. Remove the wire securing the camshaft sprocket and chain. Install the distributor drive gear with a new washer and lock bolt.7 N. Coat a new gasket with silicone sealant.4 in.5—95. MANUAL TO. Apply silicone sealant to the areas shown.m {80—110 kgf.INDEX RANG. 4. Install the cylinder head cover. Install the service cover with a new gasket. 69. 2. Tightening torque 7. Tighten the bolts A.DRFT.TO. Tighten the lock bolt. 2. Install the new seal cover.CHAPTER. Remove the retaining pin from the chain adjuster. water. and other foreign material. FROM. Cylinder Head Cover Installation Note 1. 3.

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

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

Remove the cylinder head cover.15 mm {0.15 mm {0. ENGINE OIL. Insufficient oil pressure Faulty HLA 5. If noise stops within 20 minutes*.REPAIR MANUAL PAGES. Noise during idle after high speed running.) CONTINUED B1-12 .) 4. OIL PRESSURE INSPECTION) Press down HLA by hand. 3. replace HLA. 3. FROM. HLA TROUBLESHOOTING. CYLINDER HEAD GASKET REPLACEMENT. HLA REMOVAL/INSTALLATION. (Refer to CYLINDER HEAD GASKET. ENGINE OIL. Install the cylinder head cover.TO. ENGINE OIL REPLACEMENT.DRFT. If valve clearance is more than 0.INDEX RANG. (Refer to CYLINDER HEAD GASKET. Oil leakage in HLA Possible Cause Oil leakage in oil passage or in HLA Action Run engine at 2. HLA REMOVAL/INSTALLATION. (Refer to HYDRAULIC LASH ADJUSTER (HLA). Incorrect oil amount Deteriorated oil Valve Clearance Inspection 1.000—3. (Refer to section D. Noise when engine is started immediately after oil is changed.) 2.BACK.000 rpm. Noise when engine is started after sitting one day or more. (Refer to HYDRAULIC LASH ADJUSTER (HLA). HLA is normal. Valve Clearance Inspection.INDEX HYDRAULIC LASH ADJUSTER (HLA) HLA TROUBLESHOOTING Problem 1. (Refer to HLA. replace HLA. Valve Clearance Inspection. If it moves. CYLINDER HEAD GASKET REPLACEMENT. (Refer to section D.) 2. MANUAL TO.) Replace new engine oil. 4. check for cause. Noise continues more than 10 minutes. Time required for engine oil to circulate within HLA includes tolerance for engine oil condition and ambient temperature. ENGINE OIL INSPECTION. HLA TROUBLESHOOTING. (Refer to section D.) Check oil pressure. Noise when engine is started after new HLA is installed. If not. HLA is normal.) Measure valve clearance. If lower than specification. Measure valve clearance. Valve clearance 0.CHAPTER. Cylinder Head Cover Installation Note. If it does not move.0059 in}. (Refer to HYDRAULIC LASH ADJUSTER (HLA).0059 in} max. replace the HLA.) Check oil level. MODEL .

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

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

Remove the radiator. and fuel leakage. (Refer to section N.) 11.) 1. BEFORE REPAIR PROCEDURE. (Refer to section E.CHAPTER. COOLING SYSTEM SERVICE WARNINGS. (Refer to section F1. Disconnect the fuel hoses. To prevent this. CONTINUED B1-15 .) 7. Fuel can also irritate skin and eyes. Remove the drive belt. (Refer to section F1. Remove the front pipe.REPAIR MANUAL PAGES. ENGINE SPEED SENSING POWER STEERING. and vacuum hoses. It can very easily ignite. (Refer to DRIVE BELT.) 8. Remove the P/S oil pump with the oil hose still connected. bracket. ENGINE COOLANT REPLACEMENT. Start the engine and (1) check the engine oil. ENGINE COOLANT. BEFORE REPAIR PROCEDURE. MANUAL TRANSMISSION.TO. engine coolant. Position the P/S oil pump so that it is out of the way.) 10.) (Refer to section E. FROM. always complete the "Fuel Line Safety Procedure" in section F1. 12. Install in the reverse order of removal.DRFT. (Refer to section F1. heater hoses. transmission oil. (Refer to section J2.INDEX ENGINE ENGINE ENGINE REMOVAL/INSTALLATION RANG. MANUAL TO. (Refer to section E. Remove the air cleaner and fresh-air duct. POWER STEERING OIL PUMP REMOVAL/INSTALLATION. AFTER REPAIR PROCEDURE. 13. 6. RADIATOR REMOVAL/INSTALLATION. Drain the engine coolant. Disconnect the negative battery cable. FUEL SYSTEM. 14. 2. Remove the transmission.) 15. • Fuel line spills and leaks are dangerous. FUEL SYSTEM. FUEL SYSTEM.) 3. Remove the A/C compressor with the pipe still connected. Remove in the order indicated in the table. Always keep sparks and flames away from fuel. Disconnect the accelerator cable. MANUAL TRANSMISSION REMOVAL/INSTALLATION.INDEX Warning • Fuel vapor is hazardous. causing serious injury and damage. MODEL . Position the A/C compressor so that it is out of the way.BACK. idle speed and idle mixture.) 9. Fuel can ignite and cause serious injuries or death and damage. ENGINE TUNE-UP. DRIVE BELT ADJUSTMENT. 4. RADIATOR. Perform a road test.) (Refer to section F1. 5. (2) check the ignition timing.

INDEX ENGINE RANG. MODEL .INDEX 1 Engine mount nut 2 Engine CONTINUED B1-16 .CHAPTER.REPAIR MANUAL PAGES.TO.DRFT.BACK. MANUAL TO. FROM.

7.) Remove the thermostat. OIL PRESSURE INSPECTION. OIL FILTER REPLACEMENT) Remove the distributor. 11. MODEL . (Refer to section F1. 8.) Remove the intake-air system.DRFT. OIL COOLER. 1 2 3 4 5 Water bypass pipe Water inlet pipe A/C compressor bracket Generator bracket P/S oil pump bracket 6 7 8 9 10 A/C idler P/S idler Oil cooler bypass pipe Generator strap Engine mount CONTINUED B1-17 .INDEX ENGINE ENGINE DISASSEMBLY/ASSEMBLY 1.) Remove the exhaust system. 2. FROM. Disassemble in the order indicated in the table. (Refer to section G. RANG. (Refer to section D. EXHAUST SYSTEM. 6. INTAKE-AIR SYSTEM.) Remove the generator. (Refer to section E.REPAIR MANUAL PAGES. THERMOSTAT REMOVAL/INSTALLATION. MANUAL TO. Assemble in the reverse order of disassembly. (Refer to section F1.CHAPTER. (Refer to section D. 10. IGNITION SYSTEM. 5.TO. OIL FILTER. INTAKE-AIR SYSTEM REMOVAL/INSTALLATION. Remove the oil pressure switch. THERMOSTAT.BACK. 9. EXHAUST SYSTEM REMOVAL/INSTALLATION.) Remove the spark plug.INDEX Remove the oil cooler. DISTRIBUTOR REMOVAL/INSTALLATION. 3. OIL COOLER REMOVAL/INSTALLATION.) Remove the oil filter. 4. (Refer to section D.

Any changes that occur after that time will not be reflected in this particular manual. FROM. 1997 1570-10-97D Section GI B TD ST CONTINUED . JAPAN CONTENTS Title General Information Engine Technical Data Special Tools © 2001 Ford/Mazda Motor Corporation PRINTED IN JAPAN. The information in this manual is current up to April. APR.MAIN.INDEX Engine Workshop Manual F8 FE FOREWORD This manual explains the disassembly. and reassembly procedures for the above-indicated engines. the contents of this manual may not exactly match the mechanism that you are currently servicing. Mazda Motor Corporation HIROSHIMA.DRFT. MANUAL TO. and correctly. quickly. MODEL . 1997. repair. you must first read this manual and any other relevant service materials carefully.BACK.REPAIR MANUAL PAGES. In order to do these procedures safely.TO.INDEX RANG. inspection. Therefore.

....... ............................7 ARRANGEMENT OF PARTS .....................................................3 UNITS ............. DISASSEMBLY .1/2 SYMBOLS ....... Gl............................................................. Gl........... FROM.....................9 ABBREVIATIONS.......................... Gl...3 TEXT SEQUENCE .... Gl................................ Gl................. have been omitted........... MODEL ................. Gl..................... Gl..1 SERVICING PROCEDURE .. Gl................................... .......... Gl.... Gl...4 NEW STANDARDS ..................7 REASSEMBLY .......7 ADJUSTMENT .. Adjustment • The procedures .. (1) Removal/Installation (2) Disassembly/Assembly (3) Replacement (4) Inspection (5) Adjustment • Simple operations which can be performed easily just by looking at the vehicle such as removal/installation of parts............TO........BACK...7 DISASSEMBLY ..................... CONTINUED Gl-1 . Gl....1 RANGE OF TOPICS ...... cleaning of parts...........................7 SPECIAL TOOLS ....................... Gl...............7 PREPARATION OF TOOLS AND MEASURING EQUIPMENT .........3 ADVISORY MESSAGES ........... Gl.... Gl....................................... Gl................... Gl...7 CLEANING OF PARTS ... Gl.....CHAPTER.. MANUAL TO........ The procedures are divided into the following five basic operations.....................DRFT.......5 FUNDAMENTAL PROCEDURES ......... Gl....... Gl........8 VISE ...................... Gl.......................... jacking....... Important points in regard to the location and contents of the procedures are explained in detail and are shown in the illustrations..............................................................................INDEX GENERAL INFORMATION HOW TO USE THIS MANUAL ....8 HOSE CLAMPS ..8 RUBBER PARTS AND TUBING ... Gl........... Gl................ Gl.............. Gl...........8 TORQUE FORMULAS ....for inspections and adjustments are divided into steps....... .. vehicle lift...............INDEX RANG.......................... SERVICING PROCEDURE Inspection.........9 CONNECTORS .......... ................... and visual inspection................REPAIR MANUAL PAGES..................... ..10 HOW TO USE THIS MANUAL RANGE OF TOPICS • This manual contains the procedures for performing all of the required service operations............8 ELECTRICAL SYSTEM ......7 INSPECTION DURING REMOVAL.................

However. symbols indicating parts which require the use of special service tools for removal/installation are also shown. and describes visual part inspection. Refer to this information when servicing the related part. there are important points or information concerning a procedure. only the removal/installation procedures which need to be performed methodically have written instructions. and sealant are shown in the overview illustration. and symbols for oil.DRFT. 2. The procedures are numbered and the part that is the main point of that procedure is shown in the illustration with the corresponding number.REPAIR MANUAL PAGES. shows how the parts fit together. FROM.TO.INDEX HOW TO USE THIS MANUAL Repair procedure 1. grease. Occasionally. It identifies the components. In addition.BACK. tightening torques. 3. MODEL .INDEX RANG. CONTINUED Gl-2 . Expendable parts.CHAPTER. Most repair operations begin with an overview illustration. MANUAL TO.

MODEL . Warning • A Warning indicates a situation in which serious injury or death could result if the warning is ignored.BACK.DRFT. Cautions.CHAPTER.INDEX RANG. Notes. Gl-3 CONTINUED . and the use of SSTs. gasket. MANUAL TO. Specifications and Upper and lower limits in this manual.TO. Note • A Note provides added information that will help you to complete a particular procedure. Specification • The values indicates the allowable range when performing inspections or adjustments. Caution • A Caution indicates a situation in which damage to the vehicle could result if the caution is ignored. etc. Example: Apply brake fluid Apply automatic transaxle / transmission fluid Apply grease Apply sealant Appropriate sealant Apply petroleum jelly Appropriate petroleum jelly Replace part O-ring. Upper and lower limits • The values indicate the upper and lower limits that must not be exceeded when performing inspections or adjustments. grease.INDEX HOW TO USE THIS MANUAL SYMBOLS • There are eight symbols indicating oil. sealant.REPAIR MANUAL PAGES. Use SST Appropriate SST ADVISORY MESSAGES You'll find several Warnings. FROM. These symbols show the points of applying or using such Symbol Meaning Apply oil Kind New appropriate engine oil or gear oil New appropriate brake fluid New appropriate automatic transaxle/transmi ssion fluid Appropriate grease TEXT SEQUENCE • The text sequence is as indicated by the arrows shown below.

For example. Positive pressure Conversion to Sl Units (Système International d'Unités) • All numerical values in this manual are based on 81 units.4 psi. quart) Imp qt (Imperial quart) Volume ml (milliliter) cc (cubic centimeter) cu in (cubic inch) fl oz (fluid ounce) Weight 9 (gram) oz (ounce) 2 • The actual converted values for 2. if the 81 unit value is 17. 2. the converted value will be rounded off to 37. consider 2.7 is used as an upper limit. converted values for the same Sl unit value may differ after 2 conversion.INDEX RANG. In the bottom specification. FROM.7—3.INDEX HOW TO USE THIS MANUAL UNITS Electrical current Electric potential Electric power Length A (ampere) V (volt) W (watt) mm (millimeter) in (inch) kPa (kilo pascal) Negative pressure mmHg (millimeters of mercury) inHg (inches of mercury) kPa (kilo pascal) kgf/cm 2 (kilogram force per square centimeter) psi (pounds per square inch) Resistance Speed Ω (ohm) rpm (revolution per minute) N•m (Newton meter) kgf•m (kilogram force per meter) Torque kgf•cm (kilogram force per centimeter) ft•lbf (foot pound) in•lbf (inch pound) L (liter) US qt (U.REPAIR MANUAL PAGES.DRFT. the converted values are rounded down if the Sl unit value is an upper limit and rounded up if the Sl unit value is a lower limit.TO. MODEL .2 kgf/cm2 .CHAPTER.2 and the value after conversion is 37. so its converted values are rounded down to 260 and 38.1—2. Numbers shown In conventional units are converted from these values. 30—38 psi } 270—310 kPa { 2. Rounding off • Converted values are rounded off to the same number of places are the Sl unit value. In the top specification. For example. so its converted values are rounded up to 270 and 39.84.8.S. Upper and lower limits • When the data indicates upper and lower limits.7 is used as a lower limit.7 kgf/cm are 264 kPa and 38. MANUAL TO.7 kgf/cm in the following specifications: 210—260 kPa { 2. 2. Therefore.7 kgf/cm2 . 39—45 psi } CONTINUED Gl-4 .BACK.

INDEX NEW STANDARDS NEW STANDARDS • Following is a comparison of the previous standard and the new standard. there is a fuel pump relay that controls pump speed. Previous Standard Abbreviation — — — — — — — — VB Air Cleaner Air Conditioning Airflow Meter Airflow Sensor Alternator ATF Thermosensor Atmospheric Pressure Battery Voltage Name Accelerator Pedal Abbreviation AP ACL A/C VAF MAF GEN — BARO B+ OC TWC WU-TWC — — — — — — — — EGI — ECU — — — — — — — — — — — — Circuit Opening Relay Clutch Position Crank Angle Sensor Crank Angle Sensor 2 Diagnosis Connector Diagnosis/Self-Diagnosis Direct Ignition EC-AT Control Unit Electronic Gasoline Injection System Electronic Spark Ignition Engine Control Unit Engine Modification Engine RPM Signal Evaporative Emission Exhaust Gas Recirculation Fan Control Feedback System Flexible Fuel Fuel Pump Fully Closed Fully Open Ground/Earth 1C Regulator FPR CPP CMP CKP DLC OBD DLI TCM CIS El PCM ECM EM — EVAP EGR FC CLS FF FP CTP WOT GND VR Air Cleaner Air Conditioning Volume Air Flow Sensor Mass Air Flow Sensor Generator Transmission (Transaxle) Fluid Temperature Sensor Barometric Pressure Battery Positive Voltage Oxidation Catalytic Converter Three Way Catalytic Converter Warm Up Three Way Catalytic Converter Fuel Pump Relay Clutch Pedal Position Camshaft Position Sensor Crankshaft Position Sensor Data Link Connector On-Board Diagnostic Distributorless Ignition Transmission (Transaxle) Control Module Continuous Fuel Injection System Electronic Ignition Powertrain Control Module Engine Control Module Engine Modification Engine Speed Input Signal Evaporative Emission Exhaust Gas Recirculation Fan Control Closed Loop System Flexible Fuel Fuel Pump Closed Throttle Position Wide Open Throttle Ground Voltage Regulator #3 #4 #1 #2 New Standard Name Accelerator Pedal Remark Catalytic Converter #1: Directly connected to exhaust manifold #2: In some models.TO. #3: Controlled by the ECM/PCM #4: Device that controls engine and powertrain CONTINUED Gl-5 .INDEX RANG. MANUAL TO.CHAPTER. MODEL . FROM.BACK.DRFT. That relay is now called the fuel pump relay (speed).REPAIR MANUAL PAGES.

FROM.REPAIR MANUAL PAGES.DRFT.BACK. MANUAL TO.INDEX RANG.CHAPTER. MODEL .TO.INDEX NEW STANDARDS Previous Standard Abbreviation — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — Idle Switch Igniter Inhibitor Position Intake Air Pressure Intake Air Thermo Intercooler Knock Sensor Line Pressure Solenoid Valve Lock-up Position Malfunction Indicator Light Multiport Fuel Injection Open Loop Overdrive Oxygen Sensor Park/Neutral Range Power Steering Pressure Pulse Generator Reed Valve Secondary Air Injection System Sequential Fuel Injection Service Code(s) Spark Ignition Stoplight Switch Test Mode Throttle Body Throttle Sensor Turbocharger Vehicle Speed Sensor Vehicle Speed Sensor 1 Water Thermo 1—2 Shift Solenoid Valve Shift+A Solenoid Valve 2—3 Shift Solenoid Valve Shift+B Solenoid Valve — — — 3—4 Shift Solenoid Valve 3rd Gear — — — 3GR — Name Idle Speed Control Abbreviation IAC — ICM TR MAP IAT CAC KS — TCC MIL MFI OL 4GR HO2S O2S PNP PSP — SAPV PAIR AIR SFI DTC Dl — DTM TB TP TC VSS — ECT New Standard Name Idle Air Control Closed Throttle Position Switch Ignition Control Module Transmission (Transaxle) Range Manifold Absolute Pressure Intake Air Temperature Charge Air Cooler Knock Sensor Pressure Control Solenoid Torque Converter Clutch Malfunction Indicator Lamp Multiport Fuel Injection Open Loop Fourth Gear Heated Oxygen Sensor Oxygen Sensor Park/Neutral Position Power Steering Pressure Input/Turbine Speed Sensor Secondary Air Pulse Valve Pulsed Secondary Air Injection Secondary Air Injection Sequential Multipoint Fuel Injection Diagnostic Trouble Code(s) Distributor Ignition Brake Switch Diagnostic Test Mode Throttle Body Throttle Position Sensor Turbocharger Vehicle Speed Sensor Output Speed Sensor Engine Coolant Temperature Shift Solenoid A Shift Solenoid B Shift Solenoid C Third Gear Incorrect Gear Ratio #5 Pulsed injection Inject with compressor With heater Remark #5: Diagnostic trouble codes depend on the diagnostic test mode CONTINUED Gl-6 .

SPECIAL TOOLS • Use special tools when they are required. all parts should be disassembled in a way that will not affect their performance or external appearance and identified so that reassembly can be performed easily and efficiently. Warning • Using compressed air can cause dirt and other particles to fly out. CLEANING OF PARTS DISASSEMBLY • If the disassembly procedure is complex. deformation.REPAIR MANUAL PAGES. Wear protective eye wear " whenever using compressed air.BACK. • All parts to be reused should be carefully and thoroughly cleaned in the appropriate method. • Be sure to separate or otherwise identify the parts to be replaced from those that will be reused. ARRANGEMENT OF PARTS • All disassembled parts should be carefully arranged for reassembly. requiring many parts to be disassembled. causing injury to the eyes. INSPECTION DURING REMOVAL. FROM.DRFT. must be strictly observed in the reassembly of all parts. damage. these parts should be replaced with new ones: 1 3 5 Oil seals O-rings Cotter pins 2 4 6 Gaskets Lockwashers Nylon nuts REASSEMBLY CONTINUED GI-7 . MANUAL TO. DISASSEMBLY • When removed.TO. each part should be carefully inspected for malfunctioning. such as torques and certain adjustments. and other problems. MODEL .CHAPTER. • Standard values.INDEX FUNDAMENTAL PROCEDURES FUNDAMENTAL PROCEDURES PREPARATION OF TOOLS AND MESURING EQUIPMENT • Be sure that all necessary tools and measuring equipment are available before starting any work. If removed.INDEX RANG.

VISE RUBBER PARTS AND TUBING • Prevent gasoline or oil from getting on rubber parts or tubing. Sealant. • When using a vise.TO. 1. MANUAL TO. Choose the formula that applies to you. Hardened sealant causes leaks. Specified oil or grease should be applied at the prescribed locations (such as oil seals) before reassembly. the written torque must be recalculated due to the extra length that the SST adds to the torque wrench. I GI-8 CONTINUED . A: The length of the SST past the torque wrench drive. Oil should be applied to the moving components of parts. or both should be applied to the specified locations.CHAPTER. MODEL . gasket. position the hose clamp in the original location on the hose. Recalculate the torque by using the following formulas. parts should be installed before sealant hardens. Torque Unit N•m kgf• m kgf•cm ft•lbf in•lbf Formula N•m x [L/(L+A) ] kgf•m x [L/(L+A) ] kgf•cm x [L/(L+A) ] ft•lbf x [L/(L+A) ] in•lbf x [L/(L+A) ] ADJUSTMENT • Use suitable gauges and testers when making adjustments.DRFT. and squeeze the clamp lightly with large pliers to ensure a good fit. put protective plates in the jaws of the vise to prevent damage to parts. 3.BACK. L: The length of the torque wrench. FROM. When sealant is applied.REPAIR MANUAL PAGES.INDEX RANG.INDEX FUNDAMENTAL PROCEDURES HOSE CLAMPS • When reinstalling. TORQUE FORMULAS • When using a torque wrench-SST combination. 2.

DRFT. Inspection 1. MANUAL TO.REPAIR MANUAL PAGES. Check the terminals of waterproof connectors from the connector side. wrap a thin wire around the lead before inserting it into the terminal. 2. When a tester is used to check for continuity or to measure voltage.CHAPTER. • Connectors can be disconnected by pressing or pulling the lock lever as shown. MODEL . GI-9 CONTINUED . insert the tester probe from the wiring harness side. listen for a click that will indicate they are securely locked. Locking Connector • When locking connectors.INDEX ELECTRICAL SYSTEM ELECTRICAL SYSTEM CONNECTORS Disconnecting Connectors • When disconnecting two connectors. FROM.INDEX RANG. as they cannot be accessed from the wiring harness side. grasp the connectors. Caution • To prevent damage to the terminal.TO.BACK. not the wires.

........ FROM..................................... IN .................INDEX ABBREVIATIONS ABBREVIATIONS EX ....TO..........INDEX RANG............ MAX ...REPAIR MANUAL PAGES..DRFT...........BACK............................. Exhaust Hydraulic lash adjuster lntake Maximum Special service tool CONTINUED GI-10 .............. MODEL ..................................... HLA ....... SST .............CHAPTER............ MANUAL TO......

... CONTINUED B-1 ............................................. B-29/30 CRANKSHAFT END PLAY INSPECTION/REPAIR ................................................................................... B-31/32 ROTOR CLEARANCE INSPECTION .. VALVE SPRING INSPECTION .. DISMOUNTING .............................1 B............................ B-31 CONNECTING ROD SIDE CLEARANCE INSPECTION ............. B-30 CONNECTING ROD OIL CLEARANCE INSPECTION/REPAIR ............INDEX ENGINE ENGINE OVERHAUL SERVICE WARNING ................................................ TIMING CHAIN DISASSEMBLY/ ASSEMBLY .......................REPAIR MANUAL PAGES.... B-31 GEAR CLEARANCE INSPECTION ........................DRFT............INDEX RANG............................... Protect your skin by washing with soap and water immediately after this work.......6/12 B-12/13 B-14/16 B-17/19 B-20/22 B-23 B-23 B-23/24 B-24 B-24 B-25 B-25 B-26 B-26 CAMSHAFT END PLAY INSPECTION . Install the SST (arms and attachment) to the cylinder block holes as shown................................... CYLINDER BLOCK (I) DISASSEMBLY/ ASSEMBLY ............................................................. CYLINDER HEAD (I) DISASSEMBLY/ ASSEMBLY .....................2 B........... B.................. MOUNTING ......................................................................................................3 B..................... B-26 ROCKER ARM AND ROCKER ARM SHAFT INSPECTION ........................1 B............................................................................... ENGINE DISASSEMBLY/ASSEMBLY ............TO.... Assemble the SST (bolts...................... 2........................... ENGINE MOUNTING/DISMOUNTING .............. B-27 PISTON INSPECTION ........................................ CYLINDER BLOCK (II) DISASSEMBLY/ ASSEMBLY .................................... VALVE SEAT INSPECTION/REPAIR ......................... B-27 PISTON CLEARANCE INSPECTION/ REPAIR . B-32/33 PLUNGER SPRING INSPECTION .......... TIMING BELT DISASSEMBLY/ASSEMBLY ....................... B-30 CONNECTING ROD INSPECTION ............... ENGINE MOUNTING/DISMOUNTING MOUNTING 1.................... VALVE INSPECTION ..................... CAMSHAFT INSPECTION ........1/2 B............3/5 B.................. ENGINE INSPECTION/REPAIR .................................. and plate) to the specified positions.............. MODEL ....... CYLINDER HEAD (II) DISASSEMBLY/ ASSEMBLY ........ nuts. B-31 TENSIONER SPRING INSPECTION . B-28 PISTON RING CLEARANCE INSPECTION . and hand-tighten the SST (bolts)......... FROM.. VALVE GUIDE INSPECTION .BACK.CHAPTER....................... B-33 ENGINE OVERHAUL SERVICE WARNING Warning • Continuous exposure with USED engine oil has caused skin cancer in laboratory mice............ CAMSHAFT OIL CLEARANCE INSPECTION .... MANUAL TO........................................ B-28/29 CRANKSHAFT INSPECTION ..... VALVE GUIDE REPLACEMENT ..... B-31 PISTON AND CONNECTING ROD INSPECTION .... B-29 CRANKSHAFT OIL CLEARANCE INSPECTION/REPAIR .......... CYLINDER HEAD INSPECTION/REPAIR ...... B-26/27 CYLINDER BLOCK INSPECTION/ REPAIR ....... B-28 PISTON PIN CLEARANCE INSPECTION ......................................................................................................

lbf } DISMOUNTING • Dismount in the reverse order of mounting.BACK. Tightening torque 30–41 N. Warning • The self-locking brake system of the engine stand may not be effective when the engine is held In an unbalanced position.m.INDEX RANG. rapid movement of the engine and mounting stand handle and cause serious injury. FROM.REPAIR MANUAL PAGES.CHAPTER.m {3.DRFT. Drain the engine oil. Install the oil drain plug. 5. 7. and always hold the rotating handle firmly when turning the engine.2 kgf. 4. This could lead to sudden. 8. MANUAL TO. Adjust the SST (bolts) so that less than 20 mm {0. Tighten the SST (bolts and nuts) to affix the SST firmly.0–4. MODEL . Never keep the engine in an unbalanced position. CONTINUED B-2 .INDEX ENGINE MOUNTING/DISMOUNTING 3.79 in } of thread is exposed. 6. Make the SST (plate and arms) parallel by adjusting the SST (bolts and nuts).TO. 22–30 ft. Mount the engine on the SST (engine stand).

MODEL . FROM. MANUAL TO. tensioner spring • Refer to Assembly Note Idler CONTINUED B-3 .REPAIR MANUAL PAGES.INDEX ENGINE MOUNTING/DISMOUNTING ENGINE DISASSEMBLY/ASSEMBLY TIMING BELT DISASSEMBLY/ASSEMBLY 1. Assemble in the reverse order of disassembly. 2.BACK.CHAPTER.INDEX RANG. 1 2 3 4 5 Crankshaft pulley • Refer to Disassembly Note • Refer to Assembly Note Upper timing belt cover Lower timing belt cover Guide plate Spark plug 6 7 8 Timing belt • Refer to Disassembly Note • Refer to Assembly Note Tensioner.DRFT. Disassemble in the order indicated in the table.TO.

25 in } Tensioner.INDEX RANG. Tighten the tensioner lock bolt. Timing belt deflection New : 4. B-4 CONTINUED . or allowing oil or grease on It. Install the tensioner and tensioner spring. Be sure the tensioner does not move together with the bolt rotation. If they are not aligned. Camshaft pulley timing mark F8: 4 FE: 2 Timing Belt Assembly Note 1.5―6. Mark the timing belt rotation on the belt for proper reinstallation. forcefully twisting it. Caution • The following will damage the belt and shorten its life. 2. 6. 3. Turn the crankshaft clockwise and align the timing marks as shown.BACK. Turn the crankshaft clockwise twice and check the timing belt deflection at the point indicated by applying moderate pressure 98 N {10 kgf . Turn the crankshaft clockwise and align the timing marks as shown. 3. Tensioner Spring Assembly Note 1. 22 Ibf } If it is incorrect repeat from Timing Belt Disassembly Note. 5.16―0.INDEX ENGINE DISASSEMBLY/ASSEMBLY Crankshaft Pulley Disassembly Note • Hold the crankshaft by using the SST. Install the timing belt. Turning it inside out. Loosen the tensioner lock bolt to apply tension to the belt.5 mm {0.0―5. remove the timing belt and repeat from Timing Belt Assembly Note step 1. Do not apply tension other than that of the tensioner spring. 4. Remove the spark plug. MODEL . MANUAL TO.DRFT. Position the tensioner all the way to the intake side and temporarily secure it by tightening the lock bolt.CHAPTER. Turn the crankshaft clockwise twice and align the timing marks.TO. Camshaft pulley timing mark F8: 4 FE: 2 2. Timing Belt Disassembly Note 1.22―0.0 mm {0.REPAIR MANUAL PAGES.19 In } Used : 5. 2. FROM.

INDEX RANG. MODEL .INDEX ENGINE DISASSEMBLY/ASSEMBLY Crankshaft Pulley Assembly note • Hold the crankshaft by using the SST.DRFT. FROM. CONTINUED B-5 .BACK.TO.REPAIR MANUAL PAGES.CHAPTER. MANUAL TO.

2. Assemble in the reverse order of disassembly.REPAIR MANUAL PAGES. MODEL .INDEX ENGINE DISASSEMBLY/ASSEMBLY CYLINDER HEAD(I) DISASSEMBLY/ASSEMBLY Timing belt drive type 1. FROM.DRFT.INDEX RANG. Disassemble in the order indicated in the table. MANUAL TO.CHAPTER.BACK. 1 2 3 Cylinder head cover • Refer to Assembly Note Rocker arm • Refer to Disassembly Note • Refer to Assembly Note Camshaft pulley • Refer to Disassembly Note • Refer to Assembly Note 4 5 6 Front housing • Refer to Assembly Note Camshaft • Refer to Assembly Note Cylinder head • Refer to Disassembly Note • Refer to Assembly Note Cylinder head gasket 7 CONTINUED B-6 .TO.

INDEX RANG. 3. MODEL .INDEX ENGINE DISASSEMBLY/ASSEMBLY Rocker Arm Disassembly Note • Loosen the bolts in two or three steps in the order shown. Camshaft Pulley Assembly Note • Install the camshaft pulley on the camshaft with the knock pin fit into the hole at the timing mark. and camshaft bearing cap as shown in the figure. FROM.TO. rocker arm shafts. Front Housing Assembly Note 1. Camshaft Assembly Note • Be certain that the knock pin of the camshaft faces straight up. Tighten the bolts in two or three steps in the order shown. 2.DRFT. Camshaft pulley timing mark F8: 4 FE: 2 Cylinder Head Assembly Note • Tighten the bolts in two or three steps in the order shown. MANUAL TO. Assemble the rocker arms. Push the oil seal slightly in by hand. Rocker Arm Assembly Note 1. Cylinder Head Disassembly Note • Loosen the cylinder head bolts in two or three steps in the order shown. CONTINUED B-7 .REPAIR MANUAL PAGES.BACK. Press the oil seal in evenly by using the SST. Camshaft pulley Disassembly Note • Hold the camshaft by using a screwdriver. 2.CHAPTER. Apply clean engine oil to the oil seal.

Thickness ∅1.5―2.BACK. FROM. Apply silicone sealant to the shaded areas.INDEX ENGINE DISASSEMBLY/ASSEMBLY 3. MODEL .DRFT.060―0. Tap in the seal cap by using a plastic hammer.REPAIR MANUAL PAGES.078 in } 2. CONTINUED B-8 . Cylinder Head Cover Assembly Note 1. Install the cylinder head cover and tighten the bolts in two or three steps in the order shown.TO. MANUAL TO.INDEX RANG.0 mm {0.CHAPTER.

Disassemble in the order indicated in the table.TO. 2. MODEL .REPAIR MANUAL PAGES. FROM.DRFT.BACK. MANUAL TO. 1 2 3 4 5 Cylinder head cover • Refer to Assembly Note Chain adjuster • Refer to Disassembly Note • Refer to Assembly Note Camshaft gear • Refer to Disassembly Note Rocker arm • Refer to Disassembly Note • Refer to Assembly Note Camshaft 6 7 8 Camshaft sprocket • Refer to Disassembly Note • Refer to Assembly Note Cylinder head • Refer to Disassembly Note • Refer to Assembly Note Cylinder head gasket • Refer to Assembly Note B-9 CONTINUED .INDEX RANG. Assemble in the reverse order of disassembly.INDEX ENGINE DISASSEMBLY/ASSEMBLY Timing chain drive type 1.CHAPTER.

Install the cylinder head gasket.CHAPTER.REPAIR MANUAL PAGES. FROM. Loosen the remaining cylinder head bolts in two or three steps in the order shown. Camshaft Gear Disassembly Note 1. Cylinder Head Assembly Note 1. B-10 CONTINUED . 2. Turn the crankshaft until the FE mark of the camshaft pulley is at the top as shown. 2. MODEL .INDEX ENGINE DISASSEMBLY/ASSEMBLY Chain Adjuster Disassembly Note 1. 2. 2. Check that the crankshaft pulley timing mark is aligned with the indicator pin. 3. MANUAL TO. Tighten the remaining small cylinder head bolts. Apply silicone sealant to the shaded area of the cylinder head gasket. 3.INDEX RANG.DRFT.BACK. Pry up the washer tab. Cylinder Head Disassembly Note 1. Cylinder Head Gasket Assembly Note 1. Apply silicone sealant to the shaded area. Remove the bolt A.TO. Remove the chain adjuster. 2. Tighten the cylinder head bolts in two or three steps in the order shown. Hold the camshaft with a screwdriver as shown. Rocker Arm Disassembly Note • Loosen the rocker arm shaft bolts in two or three steps in the order shown.

Hold the camshaft with a screwdriver as shown. Apply silicone sealant to the shaded area.TO. Bent the washer tab to lock the locknut. Chain Adjuster Assembly Note 1.INDEX ENGINE DISASSEMBLY/ASSEMBLY Rocker Arm Assembly Note 1.BACK. 3. Camshaft Sproket Assembly Note 1. 2. then lock it with the pin lock. Tighten the bolt in two or three steps in the order shown.CHAPTER. CONTINUED B-11 . Install the camshaft sprocket to the camshaft. 3.DRFT. Lift the ratchet pawl and compress the chain adjuster sleeve fully. FROM. MANUAL TO. aligning mark on the camshaft sprocket and timing chain. Tap in the new seal cap by using a plastic hammer.INDEX RANG. 2. MODEL .REPAIR MANUAL PAGES.

Valve Seal Disassembly Note • Remove the valve seal by using the SST.DRFT.INDEX RANG. 2.REPAIR MANUAL PAGES.CHAPTER.TO. Apply silicone sealant to the shaded areas. Assemble in the reverse order of disassembly. 2 3 4 5 6 Valve keeper • Refer to Disassembly Note • Refer to Assembly Note Upper valve spring seat Valve spring (FE CIS: Single spring type) • Refer to Assembly Note Lower valve spring seat Valve Valve seal • Refer to Disassembly Note • Refer to Assembly Note Valve Keeper Disassembly Note • Remove the valve keeper by using the SST. 1 3. MODEL . 2. CYLINDER HEAD (II) DISASSEMBLY/ASSEMBLY 1.INDEX ENGINE DISASSEMBLY/ASSEMBLY Cylinder Head Cover Assembly Note 1.BACK. FROM. MANUAL TO. Disassemble in the order indicated in the table. CONTINUED B-12 . Install the cylinder head cover and tighten the bolts in two or three steps in the order shown. Apply silicone sealant to the seal cap as shown.

REPAIR MANUAL PAGES.756―0. FROM.2―19. 3. MANUAL TO.771 in } FE CIS: 21. CONTINUED B-13 .TO.4―22. Depth L F8.INDEX ENGINE DISASSEMBLY/ASSEMBLY Valve Spring Assembly Note • Install the valve spring with the closer pitch toward the cylinder head.843―0.874 in } Valve Keeper Assembly Note • Install the valve keeper by using the SST.BACK.6 mm {0.DRFT. Assemble the SST so that depth L is as specified. MODEL . Valve Seal Assembly Note 1. Tap the SST by using a plastic hammer until its lower end touches the cylinder head.2 mm {0. Press the valve seal onto the valve guide by hand.INDEX RANG. 2.CHAPTER. FE CARB: 19.

DRFT. Assemble in the order of disassembly.REPAIR MANUAL PAGES. Disassemble in the order indicated in the table.INDEX RANG. FROM. 1 2 3 4 5 6 7 Water pump Crankshaft pulley • Refer to Disassembly Note • Refer to Assembly Note Timing chain cover • Refer to Disassembly Note • Refer to Assembly Note Timing chain • Refer to Assembly Note Timing gear Crankshaft key Timing chain lever 8 9 10 11 12 13 14 15 16 Timing chain guide Oil strainer Oil pan • Refer to Disassembly Note • Refer to Assembly Note Oil pump cover Inner rotor Outer rotor Spring seat Pressure spring Control plunger CONTINUED B-14 .BACK. 2. MODEL . MANUAL TO.CHAPTER.INDEX ENGINE DISASSEMBLY/ASSEMBLY TIMING CHAIN DISASSEMBLY/ASSEMBLY 1.TO.

099―0. Apply silicone sealant to the mounting surface along the inside of the bolt holes as shown. _ Timing Chain Cover Disassembly Note • Remove the oil seal by using a screwdriver protected with a rag.m {3.5―3. MANUAL TO. Press the oil seal in evenly by using the SST. Push the oil seal slightly in by hand.REPAIR MANUAL PAGES.137 in } 4.9―2.5 mm {0.CHAPTER.BACK. Timing Chain Cover Assembly Note 1.INDEX RANG. Support the timing chain by using a magnetic base.8―5. FROM. Apply clean engine oil to the oil seal.INDEX ENGINE DISASSEMBLY/ASSEMBLY Crankshaft Pulley Disassembly Note • Hold the crankshaft by using the SST. 5.TO.m .m .3 kgf. 2. Oil Pan Assembly Note • Apply silicone sealant to the oil pan as shown.6 kgf.lbf } B-15 CONTINUED . Install the timing chain as shown in the figure. 14―18 ft. 28―38 ft.DRFT. Tighten the timing chain cover installation bolt. 3. Tightening torque A: 19―25 N. Oil Pan Disassembly Note • Remove the oil pan by using the separator tool. MODEL .m {1. Timing Chain Assembly Note 1.lbf } B: 38―51 N. 2. Thickness ∅2.

REPAIR MANUAL PAGES.INDEX ENGINE DISASSEMBLY/ASSEMBLY Crankshaft Pulley Assembly Note • Hold the crankshaft by using the SST. FROM.CHAPTER.INDEX RANG. MANUAL TO. CONTINUED B-16 . MODEL .DRFT.BACK.TO.

Disassemble in the order indicated in the table. MODEL .INDEX RANG.INDEX ENGINE DISASSEMBLY/ASSEMBLY CYLINDER BLOCK (I) DISASSEMBLY/ASSEMBLY 1.REPAIR MANUAL PAGES. Pressure spring (Timing belt drive type) Control plunger (Timing belt drive type) Rear cover • Refer to Disassembly Note • Refer to Assembly Note Water pump • Refer to Assembly Note 2 3 4 5 16 6 7 CONTINUED B-17 . 2.BACK.TO.DRFT. MANUAL TO. 2 1 Oil pan (Timing belt drive type) • Refer to Disassembly Note • Refer to Assembly Note Oil strainer (Timing belt drive type) Oil baffle (FE CIS) • Refer to Disassembly Note • Refer to Assembly Note Timing belt pulley (Timing belt drive type) • Refer to Disassembly Note • Refer to Assembly Note Flywheel • Refer to Disassembly Note • Refer to Assembly Note End plate Oil pump (Timing belt drive type) • Refer to Disassembly Note • Refer to Assembly Note 8 9 10 11 12 13 14 15 Oil pump body (Timing belt drive type) Outer gear (Timing belt drive type) Inner gear (Timing belt drive type) Oil pump cover (Timing belt drive type) Spring seat (Timing belt drive type) . FROM. Assemble in the reverse order of disassembly.CHAPTER.

MANUAL TO. Flywheel Disassembly Note • Hold the crankshaft by using the SST.INDEX RANG. 2. If not. FROM. Push the oil seal slightly in by hand. Timing Belt Pulley Disassembly Note • Hold the crankshaft by using the SST.BACK. CONTINUED B-18 . • Remove the oil pan by using the separator tool. 3. 2. Oil Baffle Disassembly Note • Remove the oil baffle by using the separator tool.REPAIR MANUAL PAGES. Oil Pump Disassembly Note • Remove the oil seal by using a screwdriver protected with a rag.CHAPTER. Verify that the rubber seal is securely fixed onto the water pump. Install the water pump.DRFT. Rear Cover Disassembly Note • Remove the oil seal by using a screwdriver protected with a rag. Rear Cover Assembly Note 1. Press the oil seal in evenly by using the SST.TO. Apply clean engine oil to the oil seal. 3. replace the rubber seal and reapply the bonding agent. Water Pump Assembly Note 1. MODEL .INDEX ENGINE DISASSEMBLY/ASSEMBLY Oil Pan Disassembly Note Note • Do not insert the separator tool between the oil baffle and cylinder block.

2.REPAIR MANUAL PAGES.INDEX ENGINE DISASSEMBLY/ASSEMBLY Oil Pump Assembly Note 1.079―0.079―0. FROM.0 mm {0.0 mm {0. Apply clean engine oil to the oil seal. Oil Baffle Assembly Note • Apply silicone sealant to the oil baffle as shown.118 in } CONTINUED B-19 . Tighten the flywheel bolt in the order shown. Thickness ∅2.BACK.CHAPTER.0―3. Hold the crankshaft by using the SST.INDEX RANG. 3. Oil Pan Assembly Note • Apply Silicone sealant to the oil pan as shown.DRFT. Push the oil seal slightly in by hand.118 in } Flywheel Assembly Note 1.TO.0―3. Thickness ∅2. 2. MANUAL TO. Press the oil seal in evenly by using the SST. MODEL . Timing Belt Pulley Assembly Note • Hold the crankshaft by using the SST.

2. MODEL .TO.BACK. Disassemble in the order indicated in the table. MANUAL TO.REPAIR MANUAL PAGES. FROM.INDEX RANG. 1 2 3 Connecting rod cap Lower connecting rod bearing Piston and connecting rod • Refer to Disassembly Note • Refer to Assembly Note Upper connecting rod bearing Piston ring Piston pin Piston Connecting rod 9 10 11 4 5 6 7 8 Main bearing cap • Refer to Disassembly Note • Refer to Assembly Note Lower main bearing Pilot bearing • Refer to Disassembly Note • Refer to Assembly Note Crankshaft Upper main bearing Cylinder block 12 13 14 CONTINUED B-20 .CHAPTER.DRFT.INDEX ENGINE DISASSEMBLY/ASSEMBLY CYLINDER BLOCK (II) DISASSEMBLY/ASSEMBLY 1. Assemble in the reverse order of disassembly.

Assemble the SST as shown. Assemble the SST as shown. 3.REPAIR MANUAL PAGES. Pilot Bearing Assembly Note • Install the pilot bearing by using a suitable pipe. Press out the piston pin.CHAPTER. Insert SST No.INDEX ENGINE DISASSEMBLY/ASSEMBLY Piston and Connecting Rod Disassembly Note 1. CONTINUED B-21 . Set the piston and connecting rod on the SST as shown. Pilot Bearing Disassembly Note • Remove the pilot bearing by using the SST. Tighten the bolts in two or three steps in the order shown. Main Bearing Cap Assembly Note 1. Piston and Connecting Rod Assembly Note 1. FROM. MODEL .DRFT. 4.2 into the piston pin as shown and fully screw in SST No.1.INDEX RANG. 2.BACK. Main Bearing Cap Disassembly Note • Loosen the main bearing cap bolts in two or three steps in the order shown. MANUAL TO.TO.

TO. replace the piston pin or the connecting rod.36 in } 8.CHAPTER. check the pressure force.2 into the piston pin as shown and fully screw in SST No.INDEX ENGINE DISASSEMBLY/ASSEMBLY 2. Verify that the second ring is installed with the scraper face downward. Press the piston pin into the piston and connecting rod until the SST (guide) contacts the SST (stopper bolt). If it is less than the specification. While inserting the piston pin. Insert SST No.INDEX RANG. 6.1. Set the SST (stopper bolt) so that dimension L is as specified.REPAIR MANUAL PAGES.DRFT. Apply clean engine oil to the piston pin.BACK. Dimension L 60. 660―3300 Ibf } CONTINUED B-22 . 9. 3.0 mm {2. FROM. MODEL .94―14. 5. Pressure force 2. 10. 7. MANUAL TO. Insert the piston pin and the SST assembled in step 2 into the piston and connecting rod. F mark facing the front of the engine.70 KN {300―1500 kgf . Position the end gap of the oil ring as shown. 4.

grind the surface or replace the cylinder head .045 mm {0.2745―0.3160―0. Standard diameter FE CIS IN: 6. FE CARB IN: 7.BACK.386 in} EX: 111. If the cylinder head height is not within the specification.568―4.008 in } max. If the distortion exceeds the specification.390―4.006 in } max.3162―0.09 mm {4. Distortion 0.15 mm {0.2743―0.624 in } Grinding 0.412} EX: 111. Distortion 0. 5.2 mm {0. repair by grinding the height or replace the cylinder head.30―1.15 mm {0.965―6. Replace the cylinder head if necessary. Replace the valve if necessary.556 in} F8. 2.975 mm {0. FE CARB IN: 8. MANUAL TO. Measure the cylinder head for distortion in the six directions as shown.REPAIR MANUAL PAGES. Standard height 91.006 in } F8.567 in } EX: 116.51 mm {4.548 in} EX: 115.41mm {4. Standard length FE CIS IN: 115.980 mm {0. FE CARB IN: 111.980 mm {0.7 mm {0.915 mm {0.80―2.030―8.025―8.TO.70 mm {0.01 mm {4.040 mm {0. 6.066 in } 2.3―1.89 mm {4.052―0. Margin thickness FE CIS IN: 1.INDEX RANG.405 in } Minimum length FE CIS IN: 115.047 in } EX: 1. FE CARB IN: 111. (1) Sunken valve seats (2) Excessive camshaft oil clearance and end play 3. FE CARB IN: 0.CHAPTER.2722 in } F8.20 mm {0.920 mm {0.01―116.20 mm {0.583 in } F8. 4.621―3.008 in } max. Replace the valve if necessary.970―6.3165 in } Minimum diameter FE CIS IN: 6. Inspect for the following and repair or replace if necessary.49―111. Measure the stem diameter of each valve in X and Y directions at the three points (A.69―112.95―92.032―0.20 mm {0. FROM. Measure the length of each valve. Measure the manifold contact surface distortion as shown.2749 in } EX: 6. If the cylinder head distortion exceeds the maximum.39 mm {4.398―4.006 in} max.05 mm {3. VALVE INSPECTION 1. Grinding 0. B.DRFT.2748 in } F8.2724 in } EX: 6.INDEX ENGINE INSPECTION/REPAIR ENGINE INSPECTION/REPAIR CYLINDER HEAD INSPECTION/REPAIR 1.071―0.552―4. Replace the valve if necessary.3140 in } CONTINUED B-23 .985 mm {0. and C) shown.052―0.8―1.71 mm {4.3167 in } EX: 8. Measure the valve head margin thickness of each valve.61―116.19 mm {4.086 in } EX: 1. replace it. MODEL . Carry out cooling flaw detection on the cylinder head surface.3142 in } EX: 7.378 in} 3.

3 mm {0.780―0. FE CARB: 19. Standard height FE CIS: 19.2767 in } F8.752―0.6mm {0. MODEL .752―0. Measure the inner diameter of each valve guide in X and Y directions at the three points (A.3162―0. Measure the protrusion height (dimension A) of each valve guide without lower valve spring seat.030 mm {0.8―20.2760―0. Standard inner diameter FE CIS IN: 7.799 in } F8.025―8.780―0. FE CARB: 19.771 in } 2. B. and C) shown.3165 in } Valve Guide Installation 1.2760―0.030―8. FE CARB IN: 8.INDEX RANG. CONTINUED B-24 .1―19.2767 in } EX: 7.771 in } 2.CHAPTER. Replace the valve guide if necessary.030 mm {0.752―0.8―20.040 mm {0.045 mm {0. FROM.TO. Replace the valve guide if necessary.3 mm {0.3167 in } EX: 8.6mm {0.799 in } F8. 3.799 in } FB. Depth L FE CIS: 19.REPAIR MANUAL PAGES. MANUAL TO.3 mm {0.DRFT.780―0.1―19. Standard height FE CIS: 19.BACK. Tap the valve guide in from the side opposite the combustion chamber until! the SST contacts the cylinder head.INDEX ENGINE INSPECTION/REPAIR VALVE GUIDE INSPECTION 1.010―7.711 in } VALVE GUIDE REPLACEMENT Valve Guide Removal • Remove the valve guide from the combustion chamber side by using the SST. Assemble the SSTs so that depth L is as specified. Verify that the valve guide projection height (dimension) is within the specification.8―20. FE CARB: 19.1―19.010―7.3160―0.6 mm {0.

062 in } VALVE SPRING INSPECTION 1.INDEX ENGINE INSPECTION/REPAIR VALVE SEAT INSPECTION/REPAIR 1.51 Ibf } Outer: 243. 45. 54.DRFT.02 Ibf } F8.37―272.957 in } Maximum dimension L F8. (2) If the seating position is too low. Measure the seat contact width.048―0.95―13.57― 51.437 in } Outer: 41. correct the valve seat by using a 35° (IN) or 15° (EX) cutter and a 45° cutter. Standard dimension L F8.062 in } EX: 1.6 mm {0. Valve spring out-or-square FE CIS IN: 1. If necessary. 53.03 N {24.5 mm {1.44 kgf .93―61.071 in } 3.831 in } FE CIS: 49.70 mm {0.048―0. Check the sinking of the valve seat.067 in } EX: 1.74 kgf .01 N {11.059 in } Outer: 1. Replace the valve spring if necessary.7 mm {1. MODEL .CHAPTER.56 Ibf } EX: 240.6 mm {0. 26.069 in } FB. correct the valve seat by using a 75° (FE CIS) or 60° (F8.2―1.REPAIR MANUAL PAGES.5 mm {1. Standard width IN: 1.INDEX RANG. Apply pressing force to the pressure spring and check the spring height. and a 45° cutter. Measure the out-of-square of the valve spring.8 mm {0. Replace the cylinder head if necessary.23 kgf . FE CARB) cutter.2 mm {2. FE CARB Inner: 36.03 N {24. Replace the valve spring if necessary.0 mm {1. Verify that the valve seating position is at the center of the valve face.87 kgf .71―23. Pressing force FE CIS IN: 203.76 mm {0.0 mm {1.67―59.5 mm {0.86 N {20.19―136. FE CARB Inner: 117. FE CARB Inner: 1.016 in } CONTINUED B-25 .BACK. FE CARB: 47.614 in } 2.70―267. (1) If the seating position is too high.614 in } EX: 41 mm {1. Measure the protruding length (dimension L) of the valve stem.10―229. FROM.850 in } FE CIS: 51.29―30. resurface the valve seat by using a 45° valve seat cutter and/or resurface the valve face. MANUAL TO.2―1.90 Ibf } Standard height FE CIS IN: 41 mm {1. FE CARB: 46.85―27.51―27.TO.614 in } F8. 2.

Measure the oil clearance.847 mm {1. Position a plastigage atop the journals in the axial direction. CONTINUED B-26 .INDEX ENGINE INSPECTION/REPAIR CAMSHAFT INSPECTION 1. 3. 4: 31.5040 in } EX: 38. 5: 31.5 journals on V-blocks.1 and No.7493 in } F8. Replace the camshaft if necessary.940―31.2. (Refer to ENGINE DISASSEMBLY/ASSEMBLY.DRFT. MODEL .000―19.966―15.965 mm {1.935 mm {1 .5040 in } Fuel pump cam: 39.085 mm {0. Replace the camshaft if necessary.00138―0. Measure the rocker arm shaft diameter.16 mm {0. 2.2551 in } CAMSHAFT END PLAY INSPECTION 1. Runout 0. Replace the cylinder head if necessary.202 mm {1.2585 in } No.2563―1.2572 in } Minimum diameter No.15 mm {0.2.2.984 mm {0.900 mm {1. CYLINDER HEAD (II) Camshaft Cap Assembly Note. FROM.6286―0.6276 in } EX: 41.08―0.00334 in } No. 2. Standard diameter No.00629 in } Maximum end play 0. Install the camshaft cap. 4: 0.CHAPTER.20 mm {0.033 mm {0. FE CARB IN: 38. Replace the camshaft if necessary. 4: 31.880 mm {1.115 mm {0.035―0. 5: 0. 2.2575―1.008 in } ROCKER ARM AND ROCKER ARM SHAFT INSPECTION 1.) 4.00315―0. Measure the camshaft end play.0012 in } max. Install the camshaft and thrust plate.6475 in } F8. FE CARB: 15.) 3. Measure the rocker arm inner diameter.006 in } 3. Standard clearance No. Standard height FE CIS IN: 41. Standard end play 0.00453 in } Maximum clearance 0.065―0.INDEX RANG. 3.00256―0. Measure the cam lobe height at the two points as shown.202 mm {1. Replace the camshaft and/or thrust plate if necessary.7481―0.BACK. Set the No.03 mm {0.910 mm {1.TO.910―31. Remove the camshaft cap. 3. 5: 31. Measure the camshaft runout. (Refer to ENGINE DISASSEMBLY/ASSEMBLY CYLINDER HEAD (II) Camshaft Cap Assembly Note.1.5709 in } 2. Measure the journal diameters in X and Y directions at the two points (A and B) as shown.1. Diameter FE CIS: 19. MANUAL TO.1.6292 in } CAMSHAFT OIL CLEARANCE INSPECTION 1.340 mm {1.2563 in } No.REPAIR MANUAL PAGES.

020―0.965 {3.443―86.980 mm {0.07 mm {11.959―18. Measure the distortion of the cylinder block top surface in the six directions as shown.40327―3.TO.76 in } (FE) below the top surface.380 in } F8: 268.39342―3.6286―0.215 {3.074 mm {0.25 {0.376―11.DRFT.43―268.4062} mm { in } Wear limit 0. Cylinder block height FE: 288. If the cylinder bore exceeds the wear limit.008 in } max.7472 in } F8.93―289.56 in } (F8).00240 in } CYLINDER BLOCK INSPECTION/REPAIR 1.38444} 86. 18. MODEL .465 {3. Replace the rocker arm and/or rocker arm shaft if necessary.569―10. All cylinders must be the same diameter.57 mm {10.20 mm {0. Cylinder block distortion 0.02} oversize Diameter 85.25 {0.709 in } below oil ring groove. Piston diameter mm { in } Size Standard 0.01} oversize 0.39428} 86.019 {3.000―86.50 {0.061 mm {0.00063―0.7465―0.50 {0.15 mm {0.00079―0.3865} 86.BACK.3859―3.02} oversize Diameter 86.250―86.0 mm {0.15 mm {0. FE CARB: 15. Measure the cylinder bores in X and Y directions at 65 mm {2.573 in } Grinding 0.016―0.6292 in } 3.984 mm {0.966―15. CONTINUED B-27 .40412} 2. Note • Base the boring diameter on the diameter of an oversize piston. Repair by grinding or replace if necessary. FE CARB: 0. Cylinder bore Size Standard 0.193―86.519 {3.38358―3. FROM.00291 in } F8. Calculate the rocker arm-to-shaft clearance. 70 mm {2.CHAPTER.INDEX RANG.4056―3.006 in } max.3957―3.01} oversize 0. Standard clearance FE CIS: 0.500―86.3964} 86. MANUAL TO.INDEX ENGINE INSPECTION/REPAIR Diameter FE CIS: 18.006 in } PISTON INSPECTION • Measure the outer diameter of each piston at a right angle (90°) to the piston pin.269 {3.943―85. replace the cylinder block or rebore the cylinder and install the oversize pistons so that the specified piston-to-cylinder clearance is obtained.REPAIR MANUAL PAGES. 3.

30 mm {0. If the piston is replaced.INDEX RANG. Standard diameter 21.0027 in } Second : 0. Standard clearance Top : 0. Standard diameter 21.006―0.35 mm {0.07 mm {0.70 mm {0.8639―0. C. Calculate the piston-to-cylinder clearance. Calculate the piston pin-to-piston pin bore clearance.008―0.07 mm {0.974―21.0014―0.035―0. PISTON RING CLEARANCE INSPECTION 1.076 mm {0. and D) as shown. Measure the piston ring-to-ring land clearance around the entire circumference. MODEL .20―0. Measure each connecting rod small end inner diameter in X and Y directions as shown. MANUAL TO.BACK. Insert the piston ring into the cylinder by hand and use the piston to push it to the bottom of the ring travel. FROM.008―0.8653 in } 4.20―0.943―21.15―0.0012―0.0012―0.961 mm {0. Replace the piston ring if necessary.0012―0.006 in } PISTON PIN CLEARANCE INSPECTION 1.07 mm {0.013 in } Second : 0. Replace the piston and/or piston pin if necessary.8652―0.998 mm {0.0029 in } Maximum clearance 0. Replace the piston or rebore the cylinders to fit an oversized piston if necessary.CHAPTER.REPAIR MANUAL PAGES.INDEX ENGINE INSPECTION/REPAIR PISTON CLEARANCE INSPECTION/REPAIR 1. Measure each piston pin diameter in X and Y directions at the four points (A.006 in } 2. 3.8660 in } 2. B. Standard clearance 0.980 mm {0.15 mm {0.TO.011 in } Oil rail : 0.15 mm {0. Standard diameter 21.0027 in } Maximum clearance 0. Measure each piston pin hole diameter in X and Y directions at the four points (A. Measure each piston ring end gap by using a feeler gauge.8657―0.039 in } 3.0 mm {0. Standard end gap Top : 0.DRFT. the piston rings must also be replaced.0027 in } Oil : 0. B. CONTINUED B-28 .8646 in } 2.027 in } Maximum end gap 1. Replace the piston and piston ring if necessary.03―0. C.03―0.03―0. and D) as shown.988―21.

02} undersize 0.DRFT.205 {2.025―0. Measure the main journal oil clearance.955 {2.3604} No.0.CHAPTER.) 3. Standard clearance . 2. 5 : 59.REPAIR MANUAL PAGES.0060} 50. (Refer to ENGINE DISASSEMBLY/ASSEMBLY. CYLINDER BLOCK (II) DISASSEMBLY/ASSEMBLY.01} undersize CRANKSHAFT OIL CLEARANCE INSPECTION/ REPAIR .3305} No. 5 : 59.9864} 50.002 in } max.00032―0.3604} No. Replace the crankshaft if necessary.3 : 59. Replace the crankshaft or grind the journal and install the undersize bearing if necessary. 2.01} undersize 0.50 {0.705 {1.687―59.9760―1.440―50. FROM.455 {1.TO.00099―0.3407} No. Replace the connecting rod or piston pin.437―59. 1.00291 in } No. 4.75 {0.037―0.3404} No.25 {0. MODEL .031―0. Standard oil clearance No. replace the main bearing or grind the main journal and install the undersize bearings so that the specified oil clearance is obtained.074 mm {0.205 {1.03 mm {0. 2.9765} mm { in } Out-of-round 0.024 mm {0.955 {2.687―59.074 mm {0.3401―2.3598―2.1.3302―2.0012 in } Crank pin Bearing size Standard 0. Install the main bearing cap.0056―2. Measure the journal diameter in X and Y direction at the two points (A and B) as shown.690―50.3 : 59.05 mm {0.955 {2.1.1. Main journal Bearing size Standard Diameter No.00094 in } 5. Position a plastigauge atop the journals in the axial direction.10 mm {0. 4.187―59.197 {2. 2. 2.00123―0. 5: 0.3 : 59.03} undersize Diameter 50.INDEX ENGINE INSPECTION/REPAIR Standard clearance 0.03} undersize Out-of-round 0.0006 in } CRANKSHAFT INSPECTION 1. 4.50 {0.455 {2. Calculate the connecting rod small end-to-piston pin clearance.3500} No.190―50.002 in } max.008―0.187―59. 4.3502} No. Runout 0. 2. 4.3302―2.013 mm {-0.02} undersize 0. Remove the main bearing cap.3 : 59. Main Bearing Cap Assembly Note.940―50.1.3401―2.1.937―59. MANUAL TO.9957―1. CYLINDER BLOCK (II) DISASSEMBLY/ASSEMBLY.447 {2. Main Bearing Cap Disassembly Note. CONTINUED B-29 .9962} 50.937―59.00291 in } Maximum oil clearance 0.3309} mm { in } 0. If the clearance exceeds the maximum.691 {2.437―59.3598―2.BACK.3499―2. 5 : 59.9859―1.3499―2. 5 : 59.75 {0.0014―0. (Refer to ENGINE DISASSEMBLY/ASSEMBLY.) 4.697 {2. Measure the crankshaft runout.INDEX RANG.05 mm {0.004 in } 0. 2.3: 0.25 {0.

15 mm {0.139 {0.INDEX ENGINE INSPECTION/REPAIR mm { in } Bearing size Standard 0.00708 in } Maximum end play 0.95―152.) CONNECTING ROD INSPECTION • Measure each connecting rod for bending and distortion.DRFT.09405} No. 5 : 2. /50 mm {1.01} undersize 0.379―2.BACK.1019} 28.356 in } CONTINUED B-30 .18 mm {0.08421} No.50 {0.07890―0. 5 : 2.07901} 2.95―136.20―28.08874―0. MANUAL TO. Replace the connecting rod if necessary.02} undersize 0.94―27. mm { in } Bearing size Standard 0. Install the main bearing cap.180 mm {0.17 {1. FROM.25 {0. 2.02} undersize 0.97 in } Center-to-center distance FE: 151. 2. /100 mm {3.1.08382―0.CHAPTER.25 {1.264 {0. Main Bearing Cap Disassembly Note.75 {0.382 {0.937 in } Distortion 0.3 : 2.353―5. MODEL .007 {0.254―2. (Refer to ENGINE DISASSEMBLY/ASSEMBLY.389 {0. replace the crankshaft bearing or grind the crankshaft and Install an undersize bearing so that the specified end play is obtained.75 {0. Standard end play 0.25 {0.1000―1.08885} No.08874―0.99 {1.1 040―1.986 in } F8: 135. CYLINDER BLOCK (II) DISASSEMBLY/ASSEMBLY.30 mm {0.983―5.09367―0.INDEX RANG.12―28.379―2. Remove the main bearing cap.01} undersize Bearing thickness 2.50 {0.1122} 3.09 {1.004―2. 4.0071 in } max.09377} 0. (Refer to ENGINE DISASSEMBLY/ASSEMBLY.129―2. 4.05 {5.1090} 28. CYLINDER BLOCK (II) DISASSEMBLY/ASSEMBLY. Measure the crankshaft end play.03} undersize CRANKSHAFT END PLAY INSPECTION/REPAIR 1.1071―1.1 060} 28.257 {0.1.REPAIR MANUAL PAGES.03} undersize Bearing thickness 27.254―2.09367―0.TO.00315―0.3 crankshaft bearing replace all of the bearing as a set.006 in } max.05 {5.3 : 2.04―28.1103―1.012 in } Note • When replacing the No.) 2. If the end play exceeds the maximum. Bending 0.08―0.08913} No. Main Bearing Cap Assembly Note.

30 mm {0.880―1.0692} 1.067 mm {0. Replace the connecting rod and cap if necessary.48 in } FE CARB: 56. replace the connecting rod bearing or grind the crankpin and use undersize bearings so that the specified clearance is obtained. MANUAL TO. Position a plastigauge atop the journals in the axial direction. FE CARB Timing Belt Drive Type • Measure the following clearance.635 {0.010 in } Maximum clearance 0. CYLINDER BLOCK (II) DISASSEMBLY/ASSEMBLY. If the large end does not drop by its own weight.262 mm {0.9 mm {2.DRFT. PISTON AND CONNECTING ROD INSPECTION • Check the oscillation torque as shown. 4. (Refer to ENGINE DISASSEMBLY/ASSEMBLY.380 mm {0.75 {0.110―0. (Refer to ENGINE DISASSEMBLY/ASSEMBLY.012 in } GEAR CLEARANCE INSPECTION F8.0149 in } Maximum innergear tooth tip to cresent crearance 0.9 mm {2.REPAIR MANUAL PAGES.0642―0. Remove the connecting rod cap. Install the connecting rod cap. replace the piston or the piston pin. Measure the crankpin oil clearance.50 {0.760 {0.630―1.0157 in } B-31 CONTINUED .0593―0. MODEL .267―0.CHAPTER.) 3. mm { in } Bearing thickness 1.885 {0.BACK.0742} TENSIONER SPRING INSPECTION • Measure the free length of the tensioner spring. Install the connecting rod cap.0026 in } Maximum oil clearance 0. Standard oil clearance 0.02} undersize 0. Measure the connecting rod large end side clearance.027―0.005―0.) 2. Piston and Connecting Rod Assembly Note.0643} 1.01} undersize 0.24 in } FE CIS: 53. If the clearance exceeds the maximum. CYLINDER BlOCK(II) DISASSEMBLY/ASSEMBLY. Replace the tensioner spring if necessary.400 mm {0. Piston and Connecting Rod Assembly Note. Free length F8: 63.0011―0.INDEX ENGINE INSPECTION/REPAIR CONNECTING ROD OIL CLEARANCE INSPECTION/REPAIR 1.505―1.25 {0. Replace the gear and/or pump body if necessary. Standard innergear tooth tip to cresent clearance 0.03} undersize 3.004 in } Bearing size Standard 0. Standard clearance 0.10 mm {0.510 {0.0691―0. 2.TO.0 mm {2.755―1. Remove the connecting rod cap. FROM.0106―0.12 in } CONNECTING ROD SIDE CLEARANCE INSPECTION 1.INDEX RANG.0741―0.0594} 1.

00248 in } Maximum body clearance 0.090―0.BACK. MANUAL TO.00248 in } Maximum side clearance 0. MODEL .004 in } CONTINUED B-32 .TO.030―0.200―0.CHAPTER.03―0.0069 in } Maximum outer gear to pump body clearance 0. Replace the rotor and/or pump body if necessary.008 in } Standard outer rotor to body clearance 0.176 mm {0.00119―0.18 mm {0.004 in } Standard side clearance 0.0079―0.004 in } Standard outer gear to pump body clearance 0.320 mm {0.09 mm {0.10 mm {0.007 in } Standard side clearance 0.030―0.0036―0. Maximum Inner rotor tooth tip to outer rotor clearance 0.20 mm {0.10 mm {0.0035 in } Maximum side clearance 0.0012―0.063 mm {0.00119―0.0138 in } ROTOR CLEARANCE INSPECTION FE CIS • Measure the following clearance.REPAIR MANUAL PAGES.INDEX RANG.10 mm {0.350 mm {0.0125 in } Maximum outer gear tooth tip to cresent clearance 0.INDEX ENGINE INSPECTION/REPAIR Standard outer gear tooth tip to cresent clearance 0.063 mm {0. FROM.DRFT.

004 in } CONTINUED B-33 .10 mm {0.044―0.007 in } PLUNGER SPRING INSPECTION • Measure the free length of the plunger spring.0069 in } Maximum outer gear to pump body clearance 0.09 mm {0.0035 in } Maximum side clearance 0.TO.084 mm {0.INDEX ENGINE INSPECTION/REPAIR FE CARB Timing Chain Drive Type • Measure the following clearance.0017―0.827 in } Standard outer gear to pump body clearance 0. Free length 46. MANUAL TO.18 mm {0.20 mm {0. Replace the rotor and/or pump body if necessary.4 mm {1. MODEL .DRFT.0033 in } Maximum Inner rotor tooth tip to outer rotor clearance 0. FROM.090―0.0035―0.008 in } Standard side clearance 0.0012―0.BACK.INDEX RANG. Replace the plunger spring if necessary. Standard Inner rotor tooth tip to outer rotor clearance 0.176 mm {0.03―0.CHAPTER.REPAIR MANUAL PAGES.

01 {4.567} F8.965—6.052—0.15 {0.09 {4.985 {0.780—0. MODEL .05 {3.980 {0. FE CARB: 46.30—1.2767} F8. MANUAL TO.3 {0.70 {0.2 {0.30 {0.20 {0.3140} FE CIS: 7.850} FE CIS: 51.2745—0.771} 1. FE CARB: 8.. 0..030 {0. 0.2724} F8....045 {0.3142} FE CIS: 6. FE CARB: 1..2749} F8.030—8.390—4.405} FE CIS: 115. FE CARB: 111. F8.831} FE CIS: 49.39 {4.548}...5 {1.REPAIR MANUAL PAGES.2760—0..771} FE CIS: 19.3165} FE CIS: 6..957} F8.552—4..3—1.412} FE CIS: 115.010—7. TD-1/4 TECHNICAL DATA Item Cylinder head Height mm Distortion mm Grinding mm Valve clearance (F8.048—0.19{4..3 {0. FE CARB: 47..624} 0. FE CARB: 7..583} F8. FE CARB: 46.066} F8..045 {0.BACK.032—0..2 {2.... FE CARB) mm { in } Valve and valve guide Margin thickness mm { in } IN EX Standard Minimum mm { in } EX Standard Minimum IN Valve stem diameter mm { in } EX Minimum IN Guide inner diameter EX IN Valve guide protrusion height mm { in } EX Standard Minimum Standard FE CIS: 1.69—112.5 {1.3165} FE CIS: 19..030—8.20 {0..556}.1—19.3162—0..6 {0..0 {1. FE CARB: 7.7 {1.71 {4.2748} F8. FE CARB: 0..3160—0.012} (Engine hot) IN Valve length Valve seat Seat contact width mm { in } Seat angle IN Seat sinking mm { in } (Valve protrusion height) EX IN EX IN EX Standard Maximum Standard Maximum CONTINUED TD-1 . FE CARB: 8. FE CARB: 8. FROM.040 {0.025—8.41 {4.6 {0.2 {2..2—1. FE CARB: 111.DRFT.025—8..066} FE CIS: 115.30 {0.621—3. FE CARB: 19.040 {0.568—4.378} FE CIS: 6.2—1...016} { in } { in } { in } IN EX Specification 91. FE CARB: 19. FE CARB: 47..799} F8.0 {1.957} F8.51 {4.386} FE CIS: 116.2767} F8.CHAPTER.752—0.TO. FE CARB: 8.95—92.052—0..2722} F8.49—111.61—116.086} F8.1—19.2743—0.6 {0.799} F8.8—1.7 {1..920 {0.062} 1.780—0.3160—0..012} (Engine hot) 0.048—0..3167} FE CIS: 6.850} FE CIS: 51.8—20.016} F8.071—0.062} 45° 45° F8.980 {0..030 {0. FE CARB: 111.975 {0.8—20.008} max.970—6..INDEX RANG. FE CARB: 111.. F8.6 {0.80—2.3167} FE CIS: 7..3162—0..INDEX TECHNICAL DATA TECHNICAL DATA .2760—0.752—0.831} FE CIS: 49.89 {4.01—116.006} max.398—4.915 {0.047} FE CIS: 1..7 {0.010—7..

614 in } (F8.87.00334} 0.08—0.20 {0. 54.56} Specification Inner: 117.15 {0.3859—3.3865} 86.2575—1.006} Camshaft Camshaft runout Lobe height mm { in } No. 3.0 mm {1.614 in } (FE CIS) EX H Inner: 36.966—15.00138—0.910 {1.03 {24.959—18.51} Outer: 243. FE CARB: 38.76 {0.23.01 {11.29—30.006} max.5 {0.5040} 31.3957—3.67—59.00256—0.85—27.5 {0.074 {0.880 {1. FE CIS: 41. MODEL .INDEX TECHNICAL DATA Item Valve spring H: 41.500—86.980 {0.910—31.29—30.16 {0.15 {0. FE CARB: 38.7481—0.380} F8: 268.069} F8.00629} 0.035—0.202 {1.940—31.966—15.614 in } (F8. 4 Maximum Camshaft end play mm { in } Standard Maximum Camshaft bearing oil clearance mm { in } Rocker arm and rocker arm shaft Rocker arm inner diameter Rocker arm shaft diameter Rocker arm to shaft clearance mm { in } mm { in } mm { in } Cylinder block Height Distortion Grinding Cylinder bore diameter mm { in } Wear limit Standard 0.847 {1.01 {11.269 {3.0 mm {1.00240} FE.93—289.437 in } Outer: 41.90} Out-of-square FE CIS: 1.6276} F8.37—272.86 {20.03 {24. 53.033 {0. 5 No.061 {0.7465—0.059} outer 1.065—0.19—136.67—59.00079—0. FE CARB: 15. 26.4056—3. FE CARB: 15.74.5 mm {1.965 {1.2.50 {0.2551} 0.020—0.2.2585} 31. FE CARB) H: 41.019 {3.44.90} Pressing force at Valve spring height H N { kgf.INDEX RANG.008} FE CIS: 19.43—268.8 {0.51} Outer: 243.DRFT.25 {0.202 {1.BACK.70—267.57—51. FE CARB) IN mm { in } EX 203.23.03 {24.93—61. 288.376—11.07 {11.20 {0.067} F8.6292} FE CIS: 0.6475} F8.87.03 {0.51—27.02} oversize mm { in } mm { in } mm { in } CONTINUED TD-2 .519 {3.085 {0.935 {1.1.00315—0.059} outer 1. 45.6286—0.2563—1.01} oversize 0.TO. 0.614 in } (FE CIS) IN H Inner: 36.0012} max.71—23.02} Inner: 117. 54. 4 IN EX Standard Minimum Standard Minimum No.000—86.70 {0.70—267.569—10.000—19.984 {0.5040} FE CIS: 41.1.6292} FE CIS: 18.2563} 31.340 {1.CHAPTER. FE CARB: Inner 1.573} 0.016—0.REPAIR MANUAL PAGES.0 mm {1.85—27.115 {0.00453} 0.4062} mm { in } 0. 86.00063—0.071} FE CIS: 1.7472} F8.5 mm {1.008} max.7493} F8.00291} F8.10—229. 26.19—136.0 mm {1.95—13.437 in} Outer: 41. FE CARB: Inner 1.57 {10. MANUAL TO. FROM.250—86.95—13. 5 Journal diameter mm { in } No. lbf } 240.3964} 86.071} mm { in } 0. 3.15 {0.8 {0.6286—0.984 {0.2572} 31. FE CARB: 0.006} 0.

03} undersize mm { in } mm { in } 21.00291} No.012} Specification Piston-to-cylinder clearance mm { in } Piston ring Piston pin Diameter Connecting rod small end-to-piston pin clearance Piston-to-piston pin clearance Crankshaft Crankshaft runout Main journal diameter mm { in } CONTINUED TD-3 . 2.3604} No.006—0.205 {2.39342—3. 4.25 {0.006} 0.3: 59.027} 1.0027} 0.187—59.02} undersize 0.025—0.02} oversize Standard Maximum Top Piston ring-to-ring groove clearance mm { in } Second Oil Maximum Top End gap (Measured in cylinder) mm { in } Second Oil (rail) Maximum 85.002} max.215 {3.004} 0.3598—2.50 {0. 2.3500} No.9760—1.3305} No.0.35 {0.187—59.03—0.30 {0. 50.3502} No.07 {0.30 {0. 2.00123—0. MANUAL TO.024 {0.39428} 86.0.07 {0.193—86.0. 5: 59.TO.03 {0.443—86. 4.690—50.15 {0.039} mm { in } mm { in } mm { in } mm { in } Standard 0.8653} .1.CHAPTER.0014— .3401—2.0006} 0.20—0.08—0.002} max.3: 59.0012—0.031—0.15—0.008—0.3499—2.75 {0.25 {0.9957—1.1.00099—0. 4.965 {3.40412} 0. 5: 59.465 {3.955 {2.INDEX TECHNICAL DATA Item Piston Piston diameter Measured at 90° to pin bore axis and 18.205 {1.3499—2.01} undersize 0.440—50.00291} 0.00094} 0.455 {2.38444} 86.940—50.687—59.035—0. No.008—0.3407} No.0060} 50.955 {2.9962} 50. MODEL . 5: 0.03} undersize Out-of-round Standard Crankpin diameter mm { in } Out-of-round Main journal oil clearance mm { in } Crankshaft end play mm { in } Standard Maximum Standard Maximum 0.9864} 50.0027} 0. No.INDEX RANG.20—0.03—0. 4.38358—3.REPAIR MANUAL PAGES.02} undersize 0.697 {2.3: 0.75 {0.937—59.197 {2.955 {2.691 {2.076 {0.705 {1.9859—1. 5: 59.437—59. FROM.25 {0.07 {0.10 {0.50 {0. 4.3302—2.3404} No.3: 59.9765} 0.3598—2.943—85.40327—3.0014—0. 5: 59.01} oversize 0.BACK.50 {0.03—0.0012—0.1.074 {0.DRFT.447 {2.074 {0.0012—0.687—59.00032—0.05 {0.455 {1.70 {0.013} 0.437—59.3: 59.008—0.3302—2.037— .011} 0.013 { -0.15 {0.0056—2.937—59.709 in } below oil ring groove mm { in } Standard 0.00315—0.1.0012} max.0027} 0.190—50.05 {0.0 mm {0. 2. 2.3309} 0.3604} No.3401—2.18 {0.1.006} 0.980 {0.00708} 0.8652—0.0029} 0.0 {0.01} undersize 0.974—21.

CARB Timing chain type: 0.067 {0.0106—0.24}.353—5.18 {0.20 {0.03—0.937 in} 0.00248} 0.0138} 0.200—0.400 {0. FE CARB Timing belt drive type: 0.0011—0. MANUAL TO. FE CARB: 56.012} 0.4 {1.007} (FE CIS. FE CARB Timing chain drive type: 0.0017—0.176 {0.0035—0. FE CARB Timing belt drive type: 0.008} F8.30 {0.0 {2.004} F8: 63.0079—0.TO.0125} F8. FE CARB Timing belt drive type: 0.INDEX RANG.0035} 0. FE CARB Timing chain type) FE CIS.030—0.827} Tensioner spring Free length mm { in } Oil pump Inner rotor tooth tip to outer rotor clearance mm { in } Outer rotor to body clearance mm { in } Standard Maximum Standard Maximum Standard Maximum Standard Maximum Standard Maximum Standard Maximum Inner gear tooth tip to crescent clearance mm { in } Outer gear tooth tip to crescent clearance mm { in } Outer gear to pump body clearance mm { in } Side clearance mm { in } Plunger spring Free length CONTINUED TD-4 .12} FE CARB Timing chain drive type: 0.0069} FE CIS.986} 0.CHAPTER.9 {2.10 {0.983—5.004} F8.084 {0.0026} 0.0071} max. FE CARB Timing belt drive type: 0.027—0. FROM./100 mm {3. FE CIS: 53.0157} P8.97 in } 0.350 {0.006} max.00120—0./50 mm {1.9 {2.15 {0.267—0.110—0.REPAIR MANUAL PAGES.044—0.09 {0.005—0.0149} F8.00119—0. CARB Timing chain type: 0.063 {0.262 {0.320 {0.05 {5.010} 0.INDEX TECHNICAL DATA Item Connecting rod and connecting rod bearing Length (Center to center) Bending Distortion Connecting rod side clearance mm { in } Connecting rod bearing oil clearance mm { in } Standard Maximum Standard Maximum mm { in } mm { in } mm { in } Specification F8: 135.030—0.DRFT.10 {0.090—0.05 {5. MODEL .95—136.356} FE: 151.BACK.180 {0.0012—0.0033} 0.063 {0.48}. FE CARB Timing belt drive type: 0.0024} FE CIS.95—152.10 {0.380 {0.004} mm { in } 46.

.INDEX SPECIAL TOOLS SPECIAL TOOLS ...... MANUAL TO..... ST-1 SPECIAL TOOLS 49 0107 680A Engine stand 49 L010 1A0 Engine hanger set 49 0636 100B Valve spring lifter arm 49 B012 0A2 Pivot 49 0221 251A Valve guide remover and installer 49 S120 170 Valve seal remover 49 L012 0A2 Valve seal and guide installer 49 L011 0A0B Piston pin setting tool set 49 E011 1A0 Ring gear brake set 49 1285 071 Needle bearing puller 49 P005 204 Oil seal installer 49 S011 103 Oil seal installer CONTINUED ST-1 .........BACK....TO... MODEL .....CHAPTER........DRFT.....INDEX RANG.REPAIR MANUAL PAGES.... FROM..

0—6. . . . . . . . . . . . or at least 30 minutes after the engine has stopped.20—0. . . . . . . B2–14 DRIVE BELT DRIVE BELT INSPECTION Drive Belt Deflection Check 1. check the belt tension between any two pulleys. . .0—6. . . . . . . . . . .0 {0. . B2–1 DRIVE BELT INSPECTION . MODEL . . . WATER PUMP GENERATOR CRANKSHAFT PULLEY MEASURING POINT a 2. . . . . . GENERATOR MEASURING POINT Deflection Drive belt Generator a A/C b *New 7. . . . . .5 {0. . . . . . . . . . . . . . .REPAIR MANUAL PAGES. .49} (mm {in}) Limit 16. . . A/C CRANKSHAFT PULLEY A/C COMPRESSOR 49 9200 020A MEASURING POINT b WHEN MEASURED WHEN SET CONTINUED B2–1 . . . . . . . . . . . . . . . . . . .63} 11. . . . . . . . . . . .MAIN. B2– 9/11 FRONT OIL SEAL . .71} * A belt that has been on a running engine for less than five minutes. . . . . . . B2–11 FRONT OIL SEAL REPLACEMEN T . . . .24—0. . . . WL Turbo) DRIVE BELT . . . . . . . . .INDEX ENGINE (WL. . . (Refer to DRIVE BELT. . . . . . .INDEX RANG. . . . . . . B2–1/2 DRIVE BELT ADJUSTMENT . . . . . . . . . Apply pressure 98 N {10 kgf. . . . . adjust it. . . . . . . . . .2 {0. MANUAL TO. . . . . .32—0. . . . . .TO. . .25} 11. . . . . . B2–6/8 ROCKER ARM . . . . . . . B2–2 VALVE CLEARANCE INSPECTION/ADJUSTMENT . . 22 lbf} midway between the specified pulleys. . . . . . . . If the deflection is not within the specification. . . . . . . . . B2–2 VALVE CLEARANCE . . . . . . . . B2–3 TIMING BELT . . . . . . . . . .39} 6. .0—10. .44} 18. B2–6 CYLINDER HEAD GASKET REPLACEMENT . . . . . . . . .0 {0. . .0 {0. . . . . .0—12. . . . B2–13 ENGINE REMOVAL/INSTALLATION . .0—9. B2–4 TIMING BELT REMOVAL/INSTALLATION . . or at least 30 minutes after the engine has stopped. . . . . . . . . . . FROM. . . . . B2–2 COMPRESSION INSPECTION . . .5—11. .DRFT. . . . . . .35} 5. . DRIVE BELT ADJUSTMENT. . . . .38—0. . . . .24} 9. . . . . . . . . . . . B2– 9 ROCKER ARM REMOVAL/ INSTALLATION . . . . B2–12 ENGINE . . . . . . . . . . B2–12 REAR OIL SEAL REPLACEMENT . . . . . . . . . . . .5 {0.8 {0. . . . . . . . . .44—0. . . . . Check the drive belt tension when the engine is cold. .3 {0. . .BACK. . . . Using the SST. . .46} Used 8. . B2–11/12 REAR OIL SEAL . . .28—0.0 {0. . B2–13/14 ENGINE DISASSEMBLY/ASSEMBLY . . . Belt tension can be checked in place of belt deflection.) Drive Belt Tension Check 1. . B2–4/5 CYLINDER HEAD GASKET . . . . . Check the drive belt deflection when the engine is cold. . . . . . . . . . . . . . . .

5. 24—33} 32—46 4. Loosen the mounting bolt and locknut A. DRIVE BELT ADJUSTMENT.25 mm {0. and those of B with the No. 5.0059 in} [Engine cold] 0. 99—143} 403—519 {41—53.BACK. FROM.15 mm {0.) CONTINUED B2–2 .CHAPTER. Turn the crankshaft and align the timing mark so that the piston of the No.0098 in} [Engine hot (Reference)] A A A A/C * A belt that has been on a running engine for less than five minutes. Install the cylinder head cover.0098 in} [Engine cold] 0. If the tension is not within the specification. Adjust if necessary. (Refer to DRIVE BELT. 14—18} ENGINE FRONT B GENERATOR B B CRANKSHAFT PULLEY B a A {3.9—2. Cylinder Head Cover Installation Note.1 kgf·m. Tightening torque (locknut) 16—20 N·m {1.15 mm {0.) 3. lbf}) Limit 177 {18. 2.1 or No.25 mm {0. 86—121} 354—431 {36—44.3.) DRIVE BELT ADJUSTMENT 1. 91—116} Used 383—539 {39—55. 2. 2. 41} VALVE CLEARANCE VALVE CLEARANCE INSPECTION/ADJUSTMENT 1.) 6. Turn the crankshaft one full turn and measure the remaining valve clearances. VALVE CLEARANCE Tension Drive belt Generator *New 442—637 {45—65. Inspect the belt deflection or tension.2—4. Valve clearance IN: 0.4 cylinder is at TDC of compression.REPAIR MANUAL PAGES.INDEX DRIVE BELT.7. (Refer to CYLINDER HEAD GASKET. Measure the valve clearances A with the No. (Refer to DRIVE BELT.4 cylinder at TDC of compression.6—2.0060—0.TO.8—5. 3. If not within the specification. adjust and recheck the valve clearance. GENERATOR B A 19—25 WATER PUMP {1. adjust it.15—0. MANUAL TO. 12—15 ft·lbf} A/C 38—51 {3. CYLINDER HEAD GASKET REPLACEMENT.DRFT. Tighten the mounting bolt and locknut A.0059 in} [Engine hot (Reference)] EX:0.1 cylinder at TDC of compression.INDEX RANG. Adjust the belt deflection or tension by turning adjusting bolt B.05—0. 40} 181 {18. (Refer to DRIVE BELT. 80—96} (N {kgf. A 28—38} CRANKSHAFT PULLEY A/C COMPRESSOR FEELER GAUGE ADJUST SCREW LOCKNUT b N·m {kgf·m. Remove the cylinder head cover. DRIVE BELT INSPECTION. ft·lbf} 4.0020—0. DRIVE BELT INSPECTION.6. MODEL .

MODEL . (Refer to Section G. Warm up the engine to the normal operating temperature. they can badly burn.DRFT. a valve may be stuck or improperly seated and overhaul is required. 384} [200] 9. pour a small amount of clean engine oil into the cylinder and recheck the compression. BATTERY INSPECTION. FROM. Crank the engine and note the maximum gauge reading.REPAIR MANUAL PAGES. Turn off the engine and wait until they are cool. (2) If the compression stays low. (Refer to Section F2. 49 S010 1A0 49 S013 102 (3) If the compression in adjacent cylinders stays low. do not ground the FCV (fuel cut valve) terminal. GLOW PLUG REMOVAL/INSTALLATION. Connect the FCV (fuel cut valve) connector. GLOW PLUG REMOVAL/INSTALLATION. Disconnect the FCV (fuel cut valve) connector. If the compression in one or more cylinders is low.INDEX RANG. WL Turbo 2942 {30. the cylinder head gasket may be damaged or the cylinder head distorted and overhaul is required.CHAPTER. Compression (kPa {kgf/cm2. Remove the SST. 11. (Refer to Section F2. INTAKE AIR SYSTEM. INTAKE AIR SYSTEM. 8. Stop the engine and allow it to cool off for about 10 minutes. the piston rings.) 2. Battery.BACK. 10. Verify that the battery is fully charged. Install the SSTs into the glow plug hole.TO.INDEX COMPRESSION INSPECTION COMPRESSION INSPECTION Warning D When the engine and the oil are hot. 7.) 12. CONTINUED B2–3 . 5. 1. psi} [rpm]) Item Standard Minimum Engine WL.) 6. Recharge it if necessary. 3. Remove all the glow plugs. Fuel can ignite and cause serious injuries or death and damage. To prevent fuel from spurting out of the injection nozzle hole. or cylinder wall may be worn and overhaul is required. Warning D Fuel line spills and leaks are dangerous. (1) If the compression increases. 427} [200] 2648 {27. the piston. Check each cylinder as above. Fuel can also irritate skin and eyes. MANUAL TO. CHARGING SYSTEM. Install the glow plug. 4.

2. and align the timing marks. 3. Remove the tensioner and tensioner spring. Replace the tensioner spring if necessary.0 in} MIN. or allowing oil or grease on it will damage the belt and shorten its life. FAULTY 1.7 N·m {80—110 kgf·cm. Mark the timing belt rotation on the belt for proper reinstallation. Tighten the tensioner lock bolt.TO. 7.9—10. 8. FROM. This must be done to prevent overtensioning of the timing belt after it has been installed. ft·lbf} FREE LENGTH 1 2 3 Timing belt cover + Installation Note Tensioner. Turn the crankshaft clockwise and align the timing marks as shown. MANUAL TO. Be sure the tensioner does not move together with the bolt rotation.INDEX TIMING BELT TIMING BELT TIMING BELT REMOVAL/INSTALLATION 1.5—95. Install the timing belt. Loosen the tensioner lock bolt to apply tension to the belt. Install the tensioner.4 in·lbf} 38—51 {3. 25 mm {1.8—5. turning it inside out. If it is incorrect. 9.3. 28—38} N·m {kgf·m.INDEX RANG. 5.REPAIR MANUAL PAGES. Do not apply tension other than that of the tensioner spring.48 in} 7. Turn the crankshaft clockwise twice. TIMING MARK TENSIONER LOCK BOLT CAMSHAFT PULLEY TENSIONER SPRING TENSIONER TIMING MARK FIP PULLEY Timing Belt Removal Note Caution D Forcefully twisting the belt.DRFT. If they are not aligned. Measure the tensioner spring free length. MODEL . remove the timing belt and repeat from Timing Belt Installation Note Step 2. and hand-tighten the lock bolt. 69. tensioner spring Timing belt + Removal Note + Installation Note 2. and check the timing belt deflection as shown. 2. 3. Timing Belt Installation Note 1. 6. FAULTY FAULTY ROTATION ARROW FAULTY Caution D Overtensioning of the timing belt can cause breakage of the belt and the camshaft. TIMING MARK CAMSHAFT PULLEY TENSIONER SPRING TENSIONER TIMING MARK FIP PULLEY CONTINUED B2–4 . repeat from Timing Belt Removal Note. Disconnect the negative battery cable.BACK. 3. Turn the crankshaft clockwise and align the timing marks as shown. Remove in the order indicated in the table. tensioner spring. Verify that the FIP attaching bolts and nuts are tightened to the specified torque. Free length 63. Turn the crankshaft clockwise twice.0 mm {2. Install in the reverse order of removal.CHAPTER. 4.

39 in} at 98 N {10 kgf.CHAPTER.BACK.0 mm {0.INDEX RANG. FROM.INDEX TIMING BELT Timing belt deflection 9.TO. MANUAL TO.0—10.DRFT. MODEL .REPAIR MANUAL PAGES. 22 lbf} TENSIONER LOCK BOLT CAMSHAFT PULLEY TENSIONER SPRING TENSIONER FIP PULLEY DEFLECTION CHECKING POINT Timing Belt Cover Installation Note D Tighten the timing belt cover bolts in the order shown. CONTINUED ST B2–5 .36—0.

4 in·lbf} 18—19 {1. FUEL PRESSURE AND SERVICING FUEL SYSTEM. INTAKE-AIR SYSTEM.) 4. (Refer to DRIVE BELT. (Refer to Section F2.0.4 in·lbf} 38—51 {3. 22} + (90°—105°) + (90°—105°) 7. MODEL . Remove in the order indicated in the table. TIMING BELT REMOVAL/INSTALLATION.3.9—10. PREPARATION. EXHAUST SYSTEM REMOVAL/INSTALLATION.) 11. 9. (2) Inspect the idle speed.REPAIR MANUAL PAGES. ft·lbf} B2–6 . (WL Turbo) (Refer to Section F2. (Refer to Section F2. ENGINE TUNE-UP.7 N·m {80—110 kgf·cm. Idle Speed Adjustment. 69. Start the engine and (1) Inspect for engine oil. (Refer to COMPRESSION INSPECTION. Remove the intake manifold.INDEX CYLINDER HEAD GASKET CYLINDER HEAD GASKET CYLINDER HEAD GASKET REPLACEMENT Warning D Fuel vapor is hazardous.TO. 8.8 N·m {50—90 kgf·cm.) 10.) 5. (Refer to Section F2. (Refer to Section E. (Refer to Section F2. ENGINE OIL.INDEX RANG.5—95.) 3. causing serious injury and damage. Bleed air in the fuel line. (Refer to Section D. DRIVE BELT ADJUSTMENT. Fuel can also irritate skin and eyes. ENGINE OIL INSPECTION. 2. Drain the engine coolant. engine coolant. Adjust the drive belt deflection. Always keep sparks and flames away from fuel. Inspect the compression. To prevent this. D Fuel line spills and leaks are dangerous.) 5.0. EXHAUST SYSTEM.ENGINE COOLANT.8—2. (Refer to Section F2.8—5. COOLING SYSTEM SERVICE WARNINGS. and fuel leakage.CHAPTER.) 7. FUEL SYSTEM.) 12.DRFT. FROM. MANUAL TO. INTAKE-AIR SYSTEM REMOVAL/INSTALLATION. ENGINE COOLANT REPLACEMENT. Remove the timing belt.1—14.) 13. always complete the “Fuel Line Safety Procedures”. 44—78 in·lbf} 7. It can very easily ignite. FUEL FILTER AIR BLEEDING. Disconnect the negative battery cable.BACK. Check the engine oil level.5—95. FUEL SYSTEM. INJECTION NOZZLE REMOVAL/INSTALLATION.0—8. 69. Remove the injection nozzle.7 N·m {80—110 kgf·cm.9—10. (Refer to TIMING BELT. Fuel can ignite and cause serious injuries or death and damage. 13.) (Refer to Section E.4} 29 {3. Install in the reverse order of removal. FUEL SYSTEM. air intake pipe and breather chamber.) 6. Remove the turbocharger.) 1. 28—38} CONTINUED N·m {kgf·m.

MODEL . (mm {in}) Maximum length 102.0 mm {0.REPAIR MANUAL PAGES.8 {4.5 mm {1. 22 ft·lbf} A A Cylinder Head Gasket Installation Note D Apply silicone sealant to the cylinder head as shown. Replace the bolt if necessary.480} PAINT MARK 7.91 in} 9. Apply clean engine oil to the threads and the seat face of each bolt and install them. Measure the length of each bolt.0 mm {0.8—2.007} 113. 2.0 kgf·m.BACK. Loosen the cylinder head bolts in two or three steps in the order shown. 3.4 ft·lbf} CONTINUED B2–7 .2—113.8 {3.2—101.5 mm {1. 5. Tighten the bolts in two or three steps in the order shown in the figure.35 in} ENGINE FRONT A 4. Thickness ø2.5 {4.TO. tighten the bolts by turning each 90°—105° in the sequence shown.0 kgf·m.457—4.INDEX CYLINDER HEAD GASKET 1 2 3 Drive belt Cylinder head cover + Installation Note Cylinder head bolt + Removal Note + Installation Note Cylinder head Cylinder head gasket + Installation Note LENGTH 4 5 Cylinder Head Bolt Removal Note 1. FROM. Further tighten each bolt by turning another 90°—105°.59 in} 48.508} Tightening torque 18—19 N·m {1.1—14.0—3. 13.08—0. Cylinder head bolt Bolt head mark W N Standard length 101.DRFT.63 in} 40.0 mm {0. PAINT MARK 90°—105° 90°—105° ST Cylinder Head Bolt Installation Note 1. Put a paint mark on each bolt head.035} 114. 6.INDEX RANG. Tightening torque 29 N·m {3. Tighten bolts A. MANUAL TO.5 {4.CHAPTER. A 2.11 in} 16. Remove bolts A. Using the marks as a reference.985—4.

FROM. Tighten the cylinder head cover bolts in the order shown.DRFT. Tightening torque 5. MODEL .INDEX RANG.5—2.060—0.098 in} 2. Tighten cylinder head cover bolts A and B. 14—26 in·lbf} A ENGINE FRONT B 3.0—8. Thickness ø1.5—2.8 N·m {50—90 kgf·cm. Tightening torque 1.BACK.REPAIR MANUAL PAGES.5 mm {0. Apply silicone sealant to the cylinder head as shown. MANUAL TO.CHAPTER. 44—78 in·lbf} CONTINUED B2–8 .TO.9 N·m {15—30 kgf·cm.INDEX CYLINDER HEAD GASKET Cylinder Head Cover Installation Note 1.

Remove the air intake pipe and breather chamber. Remove in the order indicated in the table.6—2.9—10.4 in·lbf} 30—41 {3. MODEL .2.) 3. VALVE CLEARANCE INSPECTION/ADJUSTMENT + CYLINDER HEAD GASKET. ft·lbf} 1 Cylinder head cover + VALVE CLEARANCE.7 N·m {80—110 kgf·cm. 100—125 in·lbf} 16—20 {1. 5. 12—15} R SST 7.REPAIR MANUAL PAGES.3—14. 5.CHAPTER. CYLINDER HEAD GASKET REPLACEMENT. Install in the reverse order of removal.2 N·m {115—145 kgf·cm. INTAKE-AIR SYSTEM REMOVAL/INSTALLATION. INTAKE-AIR SYSTEM.1. FROM. 91—103} N·m {kgf·m.8 N·m {50—90 kgf·cm. 22—30} 123—140 {12. Cylinder Head Cover Installation Note Camshaft pulley + Removal Note + Installation Note 3 4 Seal plate + Installation Note Camshaft + Removal Note + Installation Note Rocker arm + Installation Note Pivot ST 5 6 2 CONTINUED B2–9 . 69. Remove the timing belt. 44—78 in·lbf} R 11.BACK.0—4.0—8.5—95.3.) 4.INDEX ROCKER ARM ROCKER ARM ROCKER ARM REMOVAL/INSTALLATION 1. (Refer to Section F2. TIMING BELT REMOVAL/INSTALLATION.INDEX RANG.5—14.DRFT. 2. MANUAL TO.TO. Disconnect the negative battery cable. (Refer to TIMING BELT.

A Camshaft Installation Note 1. ENGINE FRONT 3. oil seal surface.5—1. measure distance between the end of the cylinder head and the face of the oil seal. Tap the oil seal into the cylinder head by using the SST and a hammer. Apply silicone sealant to the front camshaft cap mounting surfaces as shown. 2.DRFT.TO.REPAIR MANUAL PAGES.0 mm {0. and camshaft thrust surface.BACK.INDEX ROCKER ARM Camshaft Pulley Removal Note D Hold the camshaft by using a wrench on the cast hexagon. To ensure that the oil seal is installed accurately. Push the oil seal slightly in by hand.INDEX RANG. 4. Tighten the camshaft cap bolts gradually in three or four steps in the order shown. Prevent sealant from getting onto the camshaft journal. Camshaft Removal Note Note D Mark the camshaft caps so that they can be reinstalled in the position from which they were removed. MODEL .CHAPTER.03 in} HAMMER CYLINDER HEAD OIL SEAL Seal Plate Installation Note D Tighten the seal plate bolts in the order shown. CONTINUED B2–10 . Apply clean engine oil to the new oil seal. Dimension A 0—4 mm {0—0. set dimension follows. D Loosen the camshaft cap bolts in three or four ENGINE FRONT steps in the order shown. 6.1 in} as 0. 5. MANUAL TO. 49 S010 001 Rocker Arm Installation Note D If a new rocker arm is used.02—0. FROM.

ft·lbf} 1 2 Drive belt Crankshaft pulley + Removal Note + Installation Note Front oil seal + Removal Note + Installation Note 3 Crankshaft Pulley Removal Note D Hold the crankshaft by using the SST. MODEL . MANUAL TO. WATER PUMP REMOVAL/INSTALLATION.INDEX RANG. Remove the upper radiator hose. (Refer to Section E. COOLING SYSTEM SERVICE WARNINGS.REPAIR MANUAL PAGES.DRFT. FROM. Inspect the engine oil level. Install in the reverse order of removal. Disconnect the negative battery cable. 2. 8. DRIVE BELT ADJUSTMENT. Caution D Turning the crankshaft after the crankshaft pulley is removed can cause the timing gear to become dislocated. 4. (Refer to Section E. Remove in the order indicated in the table.CHAPTER. 6. 49 S011 102A CONTINUED B2–11 .) 5. Adjust the drive belt deflection. Drain the engine coolant.BACK. Remove the radiator cowling and cooling fan. (Refer to DRIVE BELT. ENGINE COOLANT REPLACEMENT.) 3. 260—280} N·m {kgf·m.) SST R SST 350—390 {35—40. WATER PUMP. FRONT OIL SEAL Camshaft Pulley Installation Note D Hold the camshaft by using a wrench on the cast hexagon and tighten the pulley lock bolt. FRONT OIL SEAL FRONT OIL SEAL REPLACEMENT 1.TO. D Removing the key can cause the key groove to become misaligned.INDEX ROCKER ARM. 7. ENGINE COOLANT.) (Refer to Section E.

) RAG Front Oil Seal Installation Note 1.5 mm {0—0.INDEX FRONT OIL SEAL. 2. Apply clean engine oil to the new oil seal lip. MODEL . Cut the oil seal lip by using a razor knife. 3.) 3. HAMMER FRONT OIL SEAL Crankshaft Pulley Installation Note D Hold the crankshaft by using the SST. 2. RAG 49 S011 102A Rear Oil Seal Installation Note 1. Cut the oil seal lip by using a razor knife. (Refer to Section D. 2. 4. 2. REAR OIL SEAL Front Oil Seal Removal Note 1. Install in the reverse order of removal. measure the distance between the end of the gear case cover and the face of the front oil seal.4 mm {0—0. ENGINE OIL. To ensure that the oil seal is installed accurately.INDEX RANG. Tap the oil seal in evenly by using the SST and a hammer. Apply clean engine oil to the new oil seal lip. Remove the oil seal by using a screwdriver protected with a rag.01 in} Rear Oil Seal Removal Note 1. Inspect the engine oil level. Remove the flywheel. Tap the oil seal in evenly by using the SST and a hammer. (Refer to Section H. ENGINE OIL INSPECTION.TO. Disconnect the negative battery cable.01 in} HAMMER REAR OIL SEAL CONTINUED B2–12 . measure the distance between the end of the rear cover and the face of the rear oil seal. Push the oil seal slightly in by hand.CHAPTER. Remove the oil seal by using a screwdriver protected with a rag. 5.BACK. 4. CLUTCH UNIT REMOVAL/INSTALLATION. Push the oil seal slightly in by hand. FROM. GEAR CASE COVER SST R 1 49 S010 301 Rear oil seal + Removal Note + Installation Note 0—0. CLUTCH UNIT. To ensure that the oil seal is installed accurately.DRFT. REAR OIL SEAL REAR OIL SEAL REPLACEMENT 1. 2. Remove in the order indicated in the table. 49 S011 103 REAR COVER 0—0.REPAIR MANUAL PAGES. 4. MANUAL TO. 3.

24—33} 20—30 {2.7 N·m {100—150 kgf·cm. Install in the reverse order of removal.) 11. RADIATOR. EXHAUST SYSTEM. 86.REPAIR MANUAL PAGES.0—3.1.INDEX RANG.CHAPTER. FUEL SYSTEM.5—95. always complete the “Fuel Line Safety Procedures”. 69. FROM. MODEL . ENGINE TUNE-UP.INDEX ENGINE ENGINE ENGINE REMOVAL/INSTALLATION Warning D Fuel vapor is hazardous. engine coolant. Remove the air intake pipe. (Refer to section J2. Remove the transmission.) 10. Always keep sparks and flames away from fuel. (Refer to Section F2. Remove in the order indicated in the table.9—2. Bleed air in the fuel line. (Refer to Section G. Start the engine and (1) Inspect the engine oil.7. 19—25 {1. RADIATOR REMOVAL/INSTALLATION. Fuel can also irritate skin and eyes. BATTERY REMOVAL/INSTALLATION.9—10. causing serious injury and damage.) 9.TO. Remove the front pipe.DRFT.6.) 4. To prevent this. Adjust the drive belt deflection.) 2.) 6. DRIVE BELT ADJUSTMENT. Remove the radiator. (Refer to Section F2. (Refer to DRIVE BELT. Fuel can ignite and cause serious injuries or death and damage. INTAKE-AIR SYSTEM.) 1. Remove the battery. ft·lbf} 1 2 3 4 Cooling fan Drive belt Accelerator cable A/C compressor + Removal Note 5 6 7 P/S oil pump + Removal Note Engine mount nut Engine + Removal/Installation Note CONTINUED B2–13 .4 in·lbf} 32—46 {3. and fuel leakage.8—130 in·lbf} 7. It can very easily ignite. TRANSMISSION. 14—18} 9. (Refer to Section F2. 7. INTAKE-AIR SYSTEM REMOVAL/INSTALLATION. FUEL PRESSURE AND SERVICING FUEL SYSTEM. MANUAL TO. FUEL FILTER AIR BLEEDING. IDLE SPEED PREPARATION.7 N·m {80—110 kgf·cm. Idle Speed Adjustment. (Refer to Section E.BACK. 8. (Refer to Section F2. D Fuel line spills and leaks are dangerous. Perform a road test. (Refer to Section F2.9—14. FUEL SYSTEM.2—4.) 5. 15—22} N·m {kgf·m.) 3. CHARGING SYSTEM. TRANSMISSION REMOVAL/INSTALLATION. (2) Inspect the idle speed. EXHAUST SYSTEM REMOVAL/INSTALLATION.

6T.3. Assemble in the reverse order of disassembly. Remove the exhaust system.INDEX ENGINE A/C Compressor Removal Note D Remove the A/C compressor with the pipe still connected.INDEX RANG. 14—18} 38—51 {3. Remove the oil cooler.DRFT.7. OIL COOLER.BACK.2—1. Tightening torque 19—25 N·m {1. 9—13} ENGINE FRONT 32—46 {3.79 in}) as shown. length 20 mm {0. Position the A/C compressor so that it is out of the way. (Refer to Section F2. OIL PRESSURE INSPECTION Water pump pulley CONTINUED B2–14 . 14—18 ft·lbf} 38—51 {3. (Refer to Section F2.REPAIR MANUAL PAGES.TO. 24—33} 19—25 {1.) 4.9—2.8—5. Remove the intake-air system.8.9—2.25.) 2. MANUAL TO. MODEL . ft·lbf} 1 2 3 4 5 6 7 Drive belt Generator Idler A/C compressor bracket Engine mount bracket Oil pressure switch + Section D.) 3. P/S Oil Pump Removal Note D Remove the P/S oil pump with the oil hose still connected. INTAKE-AIR SYSTEM REMOVAL/INSTALLATION.CHAPTER.2—4.3. OIL COOLER REMOVAL/INSTALLATION. 28—38} N·m {kgf·m. FROM. (Refer to Section D. INTAKE-AIR SYSTEM. 28—38} ENGINE DISASSEMBLY/ASSEMBLY 1.6. 5. Disassemble in the ordre indicated in the table. Position the P/S oil pump so that it is out of the way. EXHAUST SYSTEM. 12—17 {1. EXHAUST SYSTEM REMOVAL/INSTALLATION. Engine Removal/Installation Note D Install the engine hanger (JE48 10 561C) to the cylinder head by using bolt (99794 0820) or (M8 1.6 kgf·m.8—5.

. B3....... B3-14 REAR OIL SEAL ...23} 10....... If the deflection is not within the specification...................0—6....22—0.... Apply pressure 98 N {10 kgf.............. DRIVE BELT ADJUSTMENT.................31} 5...7 CYLINDER HEAD GASKET REPLACEMENT .........2 COMPRESSION INSPECTION ......DRFT.........0—8........ B3-14 FRONT OIL SEAL REPLACEMENT .........TO... adjust it...... Belt tension can be checked in place of belt deflection..... B3-10/12 HLA TROUBLESHOOTING ............0—9................. B3......2/3 TIMING BELT . 22 Ibf} midway between the specified pulleys........48—0..............1 DRIVE BELT INSPECTION . Deflection Drive belt Generator P/S A/C *New 7................0 {0.. or at least 30 minutes after the engine has stopped....5—6.............INDEX RANG..... B3..0 {0. B3..........20—0...... (Refer to DRIVE BELT.....0 {0. 2.0—12...... Using the SST............40—0...1 DRIVE BELT ADJUSTMENT ............. CONTINUED B3-1 ..47} mm {in} Used 8.....BACK.........INDEX ENGINE (F2) DRIVE BELT . MODEL ........ B3-13 FRONT OIL SEAL .........28—0.......... B3-10 HLA REMOVAL/INSTALLATION .....5 {0.......... B3-4/6 CYLINDER HEAD GASKET ... B3-16/17 ENGINE DISASSEMBLY/ASSEMBLY .32—0................... check the belt tension between any two pulleys.4 TIMING BELT REMOVAL/INSTALLATION .... B3-18 DRIVE BELT DRIVE BELT INSPECTION Drive Belt Deflection Check 1..REPAIR MANUAL PAGES.. B3-16 ENGINE REMOVAL/INSTALLATION .0 {0................................7/9 HYDRAULIC LASH ADJUSTER (HLA) ............... Check the drive belt deflection when the engine is cold................. B3-15 ENGINE . B3..0 {0......25} 12...... MANUAL TO.......55} * A belt that has been on a running engine for less than five minutes........ FROM.....) Drive Belt Tension Check 1............35} 5.. B3............. or at least 30 minutes after the engine has stopped...... B3...........MAIN....0—14. Check the drive belt tension when the engine is cold...... B3-15 REAR OIL SEAL REPLACEMENT .....

Fully depress the accelerator pedal and crank the engine.0 kgf/cm . psi} [rpm] Engine type F2 CARB F2CIS 1196 {12.BACK. Be careful not to burn yourself during removal/installation of each component. If the tension is not within the specification. • If the compression increases. Recharge it if necessary. 77—99} 275—372 {28—38. FUEL SYSTEM. BEFORE REPAIR PROCEDURE. FROM. 121} [300] 858 {8.) DRIVE BELT ADJUSTMENT 1. Perform "Fuel Line Safety Procedure". 2. • If the compression in adjacent cylinders stays low. Stop the engine and allow it to cool off for about 10 minutes.3 kgf-m. 84—110} N {kgf.REPAIR MANUAL PAGES.2. Tightening torque 15—22 N-m {1. the cylinder head gasket may be damaged or the cylinder head distorted and overhaul is required. the piston rings. DRIVE BELT ADJUSTMENT. CHARGING SYSTEM.CHAPTER. kPa {kgf/cm2. Inspect compression of each cylinder. adjust it. 88—110} 373—490 {38—50. MANUAL TO. COMPRESSION INSPECTION Tension Drive belt Generator *New 510—588 {52—60. Verify that the battery is fully charged. Remove the spark plugs. (Refer to Section F3-F4. 28 psi} If the compression in one or more cylinders is low or the compression difference between cylinders exceeds the maximum.54.) 3. 115—132} 393—490 {40—50. Ibf} Used 432—509 44—52. BATTERY INSPECTION. or cylinder wall may be worn and overhaul is required. Note the maximum gauge reading. Tighten mounting bolts A and B.) Disconnect the igniter connector (F2 CIS) or ignition coil primary wire connector (F2 CARB). DRIVE BELT INSPECTION. Leave the fuel pump relay removed. • If the compression stays low. (Refer to DRIVE BELT.TO.5.DRFT. Battery. 11—16 ft-lbf} B3-2 CONTINUED . 2. they can badly burn. 124} [300] P/S A/C • • • * A belt that has been on a running engine for less than five minutes. MODEL . (Refer to Section G. 62—83} • COMPRESSION INSPECTION Warning • When the engine and the oil are hot.) Warm up the engine to the normal operating temperature.75.INDEX RANG. pour a small amount of clean engine oil into the cylinder and recheck the compression. and locknut C. the piston. Connect a compression gauge into the No. (Refer to DRIVE BELT. 97—114} 344—441 {35—45. 173} 1226 {12. Adjust the belt deflection or tension by turning the generator or adjusting bolt D. 178} [300] [300] 837 {8. • Disconnect the compression gauge. • Install the spark plugs. and locknut C.1 spark plug hole.INDEX DRIVE BELT.5—2. • • • • • • Compression Item Standard Minimum Maximum difference between cylinders • 2 196 kPa {2. Loosen mounting bolts A and B. a valve may be stuck or improperly seated and overhaul is required.

Install the fuel pump relay. CONTINUED B3-3 .INDEX RANG. MODEL .REPAIR MANUAL PAGES.DRFT. FROM.CHAPTER.INDEX COMPRESSION INSPECTION • • Connect the igniter connector (F2 CIS) or ignition coil primary wire connector (F2 CARB).BACK.TO. MANUAL TO.

6. (2) Inspect the ignition timing.INDEX TIMING BELT TIMING BELT RANG. MANUAL TO. (Refer to DRIVE BELT.) 1 2 3 4 5 Generator strap Cooling fan bracket Timing belt cover ☞ Installation Note Crankshaft pulley Guide plate 6 7 Timing belt ☞ Removal Note ☞ Installation Note Tensioner. (Refer to Section F3-F4. Remove the spark plugs. ENGINE TUNE-UP.INDEX TIMING BELT REMOVAL/INSTALLATION 1. Remove in the order indicated in the table.REPAIR MANUAL PAGES. Start the engine and (1) Inspect the pulleys and drive belt for runout and contact. FROM.BACK.DRFT. 2. Disconnect the negative battery cable. tensioner spring ☞ Installation Note CONTINUED B3-4 . IGNITION TIMING ADJUSTMENT. Remove the cooling fan and cooling fan pulley.CHAPTER. MODEL .) 4. Install in the reverse order of removal. DRIVE BELT ADJUSTMENT. 3.TO. 5. Remove the drive belt. 7.

Timing Belt Installation Note 1.CHAPTER. FROM. Tensioner. Verify that the timing belt pulley mark and camshaft pulley mark are aligned with the timing marks as shown. Measure the tensioner spring free length. 3. If not as specified. 3. Turn the crankshaft clockwise and align the timing marks. Camshaft pulley timing mark 1 RANG. Temporarily secure the tensioner with the spring fully extended. or allowing oil or grease on it will damage the belt and shorten its life.DRFT.BACK.REPAIR MANUAL PAGES. Camshaft pulley timing mark 1 Caution • Forcefully twisting the belt. Install the tensioner.INDEX 2. Loosen the tensioner lock bolt.0 mm {2.INDEX TIMING BELT Timing Belt Removal Note 1. Install the timing belt so that there is no looseness at the tension side. MANUAL TO.48 in} CONTINUED B3-5 . 2. Push the tensioner in the direction of the ar reduce tension of the timing belt and handrow to tighten the tensioner lock bolt. Tensioner Spring Installation Note 1. turning it inside out.TO. replace the tensioner spring. MODEL . Free length 63. 2. Note • Mark the timing belt rotation on the belt for proper reinstallation.

22 Ibf}.32—0. Loosen the tensioner lock bolt to apply tension to the timing belt. MODEL . FROM. Tighten the tensioner lock bolt. Inspect the timing belt deflection at the point indicated by applying moderate pressure 98 N {10 kgf.35 in} Used : 9.39 in} 8. 6. If not as specified. repeat from Timing Belt Removal Note. 5. (Refer to Timing Belt Removal Note.0—9.INDEX RANG.0—10.INDEX TIMING BELT Caution • Applying excessive tension can break the timing belt.0 mm {0. Be sure not to apply tension other than that of the tensioner spring. 3. If not. Timing belt deflection New : 8. Otherwise tension will become very high and the timing belt may break.TO. CONTINUED B3-6 . repeat from Timing Belt Removal Note.REPAIR MANUAL PAGES. MANUAL TO.CHAPTER.) Timing Belt Cover Installation Note • Tighten the timing belt cover bolts in the order shown.36—0.) Caution • Prevent the tensioner from moving with the tensioner lock bolt as it is turned. (Refer to Timing Belt Removal Note. Turn the crankshaft clockwise twice and verify that the timing belt pulley mark and camshaft pulley mark are aligned with the timing marks.DRFT. 4.BACK.0 mm {0. 7.

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

DRFT.BACK.CHAPTER.INDEX CYLINDER HEAD GASKET 1 2 Cylinder head cover ☞ Installation Note Cylinder head ☞ Removal Note ☞ Installation Note 3 Cylinder head gasket CONTINUED B3-8 .TO. FROM.INDEX RANG. MODEL .REPAIR MANUAL PAGES. MANUAL TO.

FROM.INDEX RANG. CONTINUED B3-9 . 2. Verify that the grooves on the cylinder head cover are free of oil. MANUAL TO. Apply sealant all around the cylinder head cover side of the cylinder head cover gasket surface.REPAIR MANUAL PAGES. 4.DRFT.CHAPTER. Install the cylinder head cover gasket into the cylinder head cover. Cylinder Head Cover Installation Note 1.BACK.INDEX CYLINDER HEAD GASKET Cylinder Head Bolt Removal Note • Loosen the cylinder head bolts a few turns in the order shown. water and other foreign material. Cylinder Head Bolt Installation Note • Tighten the cylinder head bolts a few turns in the order shown. Apply silicone sealant to the shaded area as shown. 3.TO. MODEL .

) 2. HLA TROUBLESHOOTING. MANUAL TO. 4.DRFT. ENGINE OIL.REPAIR MANUAL PAGES.INDEX RANG.TO. CYLINDER HEAD GASKET REPLACEMENT.) 1. (Refer to TIMING BELT. Inspect the HLA troubleshooting.INDEX HYDRAULIC LASH ADJUSTER (HLA) HYDRAULIC LASH ADJUSTER (HLA) HLA REMOVAL/INSTALLATION Caution • Removal and installation of the HLA must be carried out only when the problem cannot be solved by the HLA troubleshooting. (Refer to Section D. ENGINE TUNE-UP.CHAPTER. MODEL .) 6. 5. FROM. (Refer to HYDRAULIC LASH ADJUSTER (HLA). Remove in the order indicated in the table. TIMING BELT REMOVAL/INSTALLATION. IDLE SPEED ADJUSTMENT. ENGINE OIL INSPECTION. Remove the timing belt. HLA TROUBLESHOOTING. Inspect the engine oil level.) 7. (Refer to HYDRAULIC LASH ADJUSTER (HLA).BACK. Start the engine and (1) inspect the engine oil (2) inspect the idle speed. (Refer to Section F3—F4. Install in the reverse order of removal.) 1 Rocker arm component ☞ Removal Note ☞ Installation Note Camshaft cap (F2 CARB) ☞ Installation Note 3 Hydraulic lash adjuster (HLA) ☞ Installation Note 2 CONTINUED B3-10 .) 3. (Refer to CYLINDER HEAD GASKET. Remove the cylinder head cover.

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

DRFT. Apply silicone sealant to the shaded areas of the cylinder head as shown.CHAPTER.BACK.INDEX RANG. CONTINUED B3-12 . Install the rocker arm component. MODEL . 4. MANUAL TO. 3.INDEX HYDRAULIC LASH ADJUSTER (HLA) 2. FROM.REPAIR MANUAL PAGES.TO. Tighten the bolts a few turns in the order shown.

(Refer to section D.DRFT. HLA TROUBLESHOOTING. (Refer to Section D. replace HLA. ENGINE OIL. Remove the cylinder head cover. Valve Clearance Inspection 1. replace HLA. Valve clearance 0. 3. ENGINE OIL. If not. HLA REMOVAL/INSTALLATION. OIL PRESSURE INSPECTION. 3. If lower than specification. check for cause.INDEX RANG. If valve clearance is more than 0. Action Run engine at 2.INDEX HYDRAULIC LASH ADJUSTER (HLA) HLA TROUBLESHOOTING Problem Possible Cause 1. 2.000—3. * Time required for engine oil to circulate within HLA Noise when engine is started includes tolerance for engine oil condition and after sitting one day or more. speed running. If it does not move. Noise when engine is started Oil leakage in oil immediately after oil is passage or in HLA changed. If it moves.) 4. (Refer to CYLINDER HEAD GASKET. (Refer to HYDRAULIC LASH ADJUSTER (HLA).000 rpm. (Refer to HYDRAULIC LASH ADJUSTER (HLA). (Refer to Section D.REPAIR MANUAL PAGES. If noise stops within 20 minutes*.) Noise continues more than Insufficient oil pressure Check oil pressure.15 mm {0. Install the cylinder head cover.CHAPTER.) Measure valve clearance. (Refer to CYLINDER HEAD GASKET.) CONTINUED B3-13 . after new HLA is installed.) Noise during idle after high Incorrect oil amount Check oil level. Valve Clearance Inspection.) Deteriorated oil Replace new engine oil.) Faulty HLA Press down HLA by hand. CYLINDER HEAD GASKET REPLACEMENT. ambient temperature. ENGINE OIL INSPECTION.TO. HLA is normal. Valve Clearance Inspection.BACK.15 mm {0. CYLINDER HEAD GASKET REPLACEMENT. replace the HLA. ENGINE OIL REPLACEMENT. FROM. HLA REMOVAL/INSTALLATION.) 4. 10 minutes. MANUAL TO. HLA TROUBLESHOOTING. HLA is normal. MODEL .0059 in} max.) 2. Noise when engine is started Oil leakage in HLA (Refer to HYDRAULIC LASH ADJUSTER (HLA). Measure valve clearance. 5. (Refer to HYDRAULIC LASH ADJUSTER (HLA).0059 in}.

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

MODEL .CHAPTER. 2. 2.INDEX RANG. Apply clean engine oil to the new oil seal lip. MANUAL TO. Remove the oil seal using a screwdriver protected with a rag. CLUTCH UNIT. Install in the reverse order of removal. Remove in the order indicated in the table. Remove the flywheel. 4. Push the oil seal slightly in by hand. Disconnect the negative battery cable. FROM.INDEX REAR OIL SEAL REAR OIL SEAL REAR OIL SEAL REPLACEMENT 1.BACK. Rear Oil Seal Installation Note 1. Cut the oil seal lip using a razor knife.REPAIR MANUAL PAGES. 1 Rear oil seal • Refer to Removal Note • Refer to Installation Note Rear Oil Seal Removal Note 1.DRFT.) 3. 3. 2. CONTINUED B3-15 . Tap the oil seal in evenly using the SST and a hammer.TO. CLUTCH UNIT REMOVAL/ INSTALLATION. (Refer to Section H.

AFTER REPAIR PROCEDURE. Drain the engine coolant. To prevent this. FUEL SYSTEM. 15. and fuel leakage. (Refer to DRIVE BELT. Disconnect the accelerator cable. ENGINE SPEED SENSING POWER STEERING. high-tension leads. 6. Install in the reverse order of removal. ENGINE COOLANT.REPAIR MANUAL PAGES. 13. FROM. heater hoses. (Refer to Section E. BEFORE REPAIR PROCEDURE. transmission oil.) (Refer to Section E. 4. 5. RADIATOR REMOVAL/INSTALLATION. ENGINE TUNE-UP. Remove the cooling fan and cooling fan pulley. and vacuum hoses. (Refer to Section N. (Refer to section F3-F4. Perform a road test. Remove the air cleaner and air hose (F2. Remove the radiator. RADIATOR. FUEL SYSTEM. • Fuel line spills and leaks are dangerous. Remove the drive belt. BEFORE REPAIR PROCEDURE. (Refer to Section F3-F4. Position the P/S oil pump so that it is out of the way. MODEL . (Refer to Section J1-J2. COOLING SYSTEM SERVICE WARNINGS.BACK. Fuel can ignite and cause serious injuries or death and damage. (Refer to Section F3-F4.DRFT.) 1.INDEX ENGINE REMOVAL/INSTALLATION Warning • Fuel vapor is hazardous. always complete the "Fuel Line Safety Procedure" in section F3. CIS). engine coolant. Disconnect the negative battery cable. Fuel can also irritate skin and eyes. POWER STEERING OIL PUMP REMOVAL/INSTALLATION. Disconnect the fuel hoses.TO. bracket (F2 CIS). It can very easily ignite. DRIVE BELT ADJUSTMENT.) 7. Start the engine and (1) Inspect the engine oil. MANUAL TRANSMISSION. Position the A/C compressor so that it is out of the way. CONTINUED B3-16 . Remove the A/C compressor with the pipe still connected.CHAPTER. MANUAL TRANSMISSION REMOVAL/INSTALLATION. MANUAL TO. FUEL SYSTEM.INDEX ENGINE ENGINE RANG.) 9. causing serious injury and damage. Always keep sparks and flames away from fuel. 8. ENGINE COOLANT REPLACEMENT. F4. Remove the P/S oil pump with the oil hose still connected. Remove the front pipe.) 11. 14.) 12. Remove in the order indicated in the table. Remove the transmission.) 10.) (Refer to Section F3-F4. (Refer to Section E. (2) Inspect the ignition timing. 2. idle speed and idle mixture.) 16.) 3.

MANUAL TO. FROM.INDEX 1 Engine mount nut 2 Engine CONTINUED B3-17 .DRFT.INDEX ENGINE RANG.BACK.CHAPTER.TO.REPAIR MANUAL PAGES. MODEL .

BACK. MANUAL TO. DISTRIBUTOR REMOVAL/INSTALLATION. Remove the exhaust system. OIL PRESSURE INSPECTION. THERMOSTAT REMOVAL/INSTALLATION. (Refer to Section E.) 4. (Refer to Section F3-F4.CHAPTER. 1 2 3 4 5 Generator strap Cooling fan bracket Generator bracket Water inlet pipe Water bypass pipe 6 7 8 9 Dipstick P/S oil pump bracket Gusset plate Engine mount CONTINUED B3-18 . (Refer to Section D. 9.INDEX ENGINE RANG. Remove the distributor.DRFT. (Refer to Section D. Remove the generator. FROM. Remove the oil pressure switch.) 6.) 7.TO. 3. EXHAUST SYSTEM REMOVAL/INSTALLATION. THERMOSTAT. Disassemble in the order indicated in the table.INDEX ENGINE DISASSEMBLY/ASSEMBLY 1. MODEL . Remove the thermostat. Remove the intake-air system. (Refer to Section F3-F4. (Refer to Section G.) 5. IGNITION SYSTEM. OIL FILTER REPLACEMENT. Remove the oil filter.REPAIR MANUAL PAGES.) 2. INTAKE-AIR SYSTEM REMOVAL/INSTALLATION. EXHAUST SYSTEM. OIL FILTER.) 8. INTAKE-AIR SYSTEM. Assemble in the reverse order of disassembly.

. . . . . . . . . . OIL FILTER . ENGINE OIL . Stop the engine and wait until it becomes cool. 59—69 psi} [3. . . . Tightening torque 12—17 N·m {1. . . . . . . . 66—76 psi} [3. . . 4.23 in} WL. . OIL PAN . . . 1. . . 49 0187 280 3. . and note the gauge readings. . . . .0—6. . .000 rpm] WL Turbo : 402—480 kPa {4. ENGINE OIL REPLACEMENT . . Apply silicone sealant to the oil pressure switch threads as shown. . .000 rpm] WL : 452—529 kPa {4. . 7. . . . .REPAIR MANUAL PAGES. .0 kgf/cm2. . .078 in} 49 0187 280 4. . 8. . . . .1 kgf/cm2. . 43—56 psi} [3. . . . . . .0—4.0 mm {0. . . Oil pressure F2 : 295—392 kPa {3.040—0. . .8 kgf·m.1—4. . . . Note D The oil pressure can vary with viscosity and temperature. . . . . . . . . . . Protect your skin by washing with soap and water immediately after this work. . . . .1—4. .4 kgf/cm2.16—0. . . . F2. . . . 6. .BACK. . .MAIN.DRFT. 45—58 psi} [3. . . . . . . . . . .TO. . D When the engine and the oil are hot. FROM. . . . . . . . . . . . . . . Install the oil pressure switch before the sealant hardens. . . OIL COOLER BODY INSPECTION . OIL FILTER REPLACEMENT . If the pressure is not as specified. . . . . . . . . . . . . 9—13 ft·lbf} 10. . . . . . ENGINE OIL INSPECTION . . . .2—1. . Warm up the engine to normal operating temperature. . Screw the SST into the oil pressure switch installation hole. G6 G6 : 305—402 kPa {3. . . . . . . . . . . . . . . . . . .0—2. . . . . they can badly burn. .9 kgf/cm2. Remove the oil pressure switch. D–1 D–2 D–2 D–2 D–2 D–2 OIL COOLER . . . . . .0 mm {0. . . . MODEL . OIL PAN REMOVAL/INSTALLATION . .000 rpm] CONTINUED D–1 . . . . . . . . . . OIL COOLER REMOVAL/INSTALLATION .000 rpm] 5. D–3 D–3/4 D–4 D–4 D–4/5 OIL PRESSURE INSPECTION Warning D Continuous exposure with USED engine oil has caused skin cancer in laboratory mice. . . . . 2. . . Remove the SST. . .INDEX RANG. . . Start the engine and inspect for oil leakage. . . . . . . . . . . . MANUAL TO. . . . . WL TURBO 9. . . Run the engine at the specified speed. . .INDEX LUBRICATION SYSTEM OIL PRESSURE INSPECTION .6—5. . . inspect for the cause and repair or replace as necessary. 1. . Turn off the engine and wait until they are cool. .

1. Refill the engine oil with the specified type and amount of engine oil. 4.9 {4. Add or replace oil if necessary. 7. 6. WL Turbo 5. D Continuous exposure with USED engine oil has caused skin cancer in laboratory mice. 8. Run the engine and inspect for oil leakage.4. FROM. 4.7 {7. 2. 22—30 ft·lbf} 5. Don’t burn yourself with either.5 {5.6 {4. Install the drain plug by using a new washer. Inspect the oil level and add oil if necessary. Start the engine and inspect for oil leakage. MANUAL TO.5 {4. Inspect for the oil level and add oil if necessary. Remove the oil filler cap and the oil pan drain plug. 4.6 {5. 3. 5. Verify that the oil level is within the F and L marks on the dipstick. ENGINE OIL INSPECTION.4} 4.) (L {US qt. Wait for five minutes. MODEL . 3.0—4. 4.REPAIR MANUAL PAGES. (Refer to ENGINE OIL.CHAPTER. Drain the oil into a container.INDEX ENGINE OIL.8.DRFT. they can badly burn. ENGINE OIL REPLACEMENT Warning D When the engine and the engine oil are hot. 49 9014 001 2. Warm up the engine to normal operating temperature and stop it. 4. (Refer to ENGINE OIL. 5. 5. Remove the dipstick and inspect for oil level and condition. 3.9. Never work around or under a lifted vehicle if it is not securely supported on safety stands. Oil capacity Item OIL FILTER OIL FILTER REPLACEMENT 1.TO. 3. Position the vehicle on level ground. It can slip or fall. Apply engine oil to the O-ring and tighten the filter according to the installation directions on the side of the oil filter using the SST or the filter wrench.2 {4. causing death or serious injury. Imp qt}) Engine F2 3.8. 5.8} WL.9.1. Position the vehicle on level ground.7 {5. Tightening torque 30—41 N·m {3. Refit the oil filler cap.0} G6 4.INDEX RANG.2 kgf·m.0. Remove the oil filter by using the SST or the filter wrench.BACK. 2.7} 4.9} Oil replacement Oil and oil filter replacement Total (dry engine) CONTINUED D–2 . D A vehicle that is lifted but not securely supported on safety stands is dangerous. 4.0} 4. 3.7. Use a clean rag to wipe off the mounting surface on the oil filter body.) Note D The actual oil level may vary from the specified capacity in some cases.1.3 {6. Protect your skin by washing with soap and water immediately after this work. OIL FILTER ENGINE OIL ENGINE OIL INSPECTION 1. 4.9} 6.4} 5. 4.5} 6. ENGINE OIL INSPECTION.

Inspect the engine oil level. 6.) 9. ENGINE COOLANT.BACK. 22—36} R R 7.) (WL Turbo model. (Refer to ENGINE OIL.9—2. 2. G6 30—39 {3. 14—18} R N·m {kgf·m. ENGINE COOLANT REPLACEMENT.INDEX OIL COOLER OIL COOLER OIL COOLER REMOVAL/INSTALLATION G6.6. FROM.0. MODEL . Remove the turbocharger.) 4. (Refer to section F2. ENGINE OIL INSPECTION.) 5. Install in the reverse order of removal. Drain the engine coolant. ft·lbf} 1 2 3 4 Dipstick pipe Radiator hose Thermostat case Insulator 5 6 Oil cooler body + Installation Note Oil cooler CONTINUED D–3 . MANUAL TO.INDEX RANG.) 3.6. (Refer to section E. ft·lbf} 1 2 Water hose Nut 3 Oil cooler WL. WL TURBO R 30—49 {3. Disconnect the negative battery cable.TO. EXHAUST SYSTEM.7 N·m {80—110 kgf·cm.) 8. 22—28} N·m {kgf·m. 7. EXHAUST SYSTEM REMOVAL/INSTALLATION.0—4.9—10. (Refer to OIL FILTER. Start the engine and inspect for engine coolant leakage. OIL FILTER REPLACEMENT.0. Fill the radiator with the specified amount and type of engine coolant.9—2. Remove in the order shown in the figure. ENGINE COOLANT.0—5. 14—18} R 19—25 {1. 70—95 in·lbf} 19—25 {1.REPAIR MANUAL PAGES.DRFT.ENGINE COOLANT REPLACEMENT. WL Turbo 1. (Refer to section E. Remove the oil filter.CHAPTER. WL.

7 mm {1. 4. Drain the engine oil. WL Turbo D Tighten the mounting bolts and nuts in the order shown. ENGINE OIL REPLACEMENT.TO.7 N·m {80—110 kgf·cm.9—10.2. 70—95 in·lbf} 38—51 {3. OIL PAN Oil Cooler Body Installation Note WL.44 in} Pressure control valve spring: 54.INDEX RANG.) 6. (Refer to ENGINE OIL.8—5. Remove in the order shown in the figure. Standard free length Bypass valve spring: 36.REPAIR MANUAL PAGES. MODEL . Fill with the specified amount and type of engine oil. 2. MANUAL TO. ft·lbf} 1 2 Gusset plate Oil pan + Removal Note + Installation Note CONTINUED D–4 . 28—38} N·m {kgf·m. Replace the spring if necessary.8—5.DRFT.) 3.CHAPTER. 28—38} PRESSURE CONTROL VALVE SPRING 38—51 {3.7 mm {2. ENGINE OIL REPLACEMENT. WL Turbo D Measure the spring free length. (Refer to ENGINE OIL. Start the engine and inspect for engine oil leakage. 5.3. 22—30} 7. Install in the reverse order of removal. Disconnect the negative battery cable. F2.BACK.INDEX OIL COOLER.15 in} BYPASS VALVE SPRING 30—41 {3. OIL PAN OIL PAN REMOVAL/INSTALLATION 1. G6 OIL COOLER BODY INSPECTION WL.0—4. FROM.3.

INDEX OIL PAN Oil Pan Installation Note Caution D If the bolts are reused. 41—59} 7.0 mm {0. WL TURBO 94—115 {9. 69—85} OLD SEALANT 55—80 {5. Caution D Pry tools can easily scratch the cylinder block or oil baffle and oil pan contact surfaces. Tightening a bolt that has old sealant on it can cause bolt hole damage.REPAIR MANUAL PAGES. Apply silicone sealant to the oil pan along the inside of the bolt holes and overlap the ends. FROM. CRACKS WL.DRFT.9—10. Prying off the oil pan can also easily bend the oil pan flange.8.2. ft·lbf} 1 2 Crossmember (4WD) Oil pan + Removal Note + Installation Note Thickness Ø2. MANUAL TO. Use a separator tool to separate the oil pan. Install the oil pan before the sealant hardens.CHAPTER.11 in} OIL PAN Oil Pan Removal Note 1.TO.7 N·m {80—110 kgf·cm. remove the old sealant from the bolt threads. N·m {kgf·m.INDEX RANG. MODEL . SEPARATOR TOOL 2. Remove the oil pan mounting bolts.BACK. 70—95 in·lbf} 1.08—0.5—11.0—3. CONTINUED D–5 . 2.6—8.

. . 2. . . Flush the cooling system with water until all traces of color are gone. . . . . . . . . . RADIATOR CAP . Turn off the engine and wait until they are cool before draining the engine coolant. . . . WATER PUMP REMOVAL/INSTALLATION . . . . . . .TO. . . . . THERMOSTAT REMOVAL/INSTALLATION . WATER PUMP . . D Use only soft (demineralized) water in the coolant mixture. . . . . . . . . . Drain the coolant in the radiator reservoir. . Use only ethylene-glycol-based coolant. . . . . . . . . . . . . . . . . . Scalding coolant and steam may shoot out and cause serious injury. . . . . . . . 4. . . . Remove the radiator cap. MANUAL TO. COOLING FAN INSPECTION . . Add coolant if necessary.1 US qt. .9—10 in·lbf} Caution D The engine has aluminum parts that can be damaged by alcohol or methanol antifreeze. . 7. .MAIN. . . . Water that contains minerals will cut down on the coolant’s effectiveness. . . . . . . . . . . . . . . . .BACK. COOLING FAN . . D When the engine and the engine coolant are hot. .9—1. . Referring to the following graph and chart. . . ENGINE COOLANT LEVEL INSPECTION 1.INDEX COOLING SYSTEM ENGINE COOLANT . . . 4. . ENGINE COOLANT LEAKAGE INSPECTION . . . . . . . . . . . . . . . . Tightening torque Type A: 1. 7. . ENGINE COOLANT REPLACEMENT . . . . . . 14—26 in·lbf} Type B: 0. Step back while the pressure escapes. . . Tighten the radiator drain plug. . . . Let the system drain completely. . . . ENGINE COOLANT LEVEL INSPECTION . . . Slowly pour the coolant into the radiator up to the coolant filler port. . RADIATOR . . . . . It may also damage the engine and cooling system. . . . . . . TYPE A DRAIN PLUG TYPE B 3. . . . . . . . . . . . . . . . D When you’re sure all the pressure is gone. Filling pace 1. . D Turn off the engine and wait until it is cool. . . . be very careful when removing the cap. . . . . .9 N·m {15—30 kgf·cm. . . . . .1 N·m {9. . select proper gravity of the coolant. . . . .5—2. . . . . . . RADIATOR REMOVAL/INSTALLATION . . . they can badly burn. Verify that the coolant level is near the radiator filler neck. . 2. .REPAIR MANUAL PAGES. . . Do not use alcohol or methanol in the cooling system. . . MODEL . .DRFT. . . . . . . . . . . . . . . and remove it. THERMOSTAT INSPECTION . . .INDEX RANG. . Verify that the coolant level in the radiator reservoir is between the FULL and LOW marks. . . 6. . . . . . 3. . . . E–1 E–1 E–1/2 E–2 E–3 E–3 E–3 E–3 THERMOSTAT . .0 L {1. . . . . . . . . . or when the engine and radiator are hot is dangerous. .0—12 kgf·cm. FROM. Drain the coolant into a container. COOLING FAN REMOVAL/INSTALLATION . . . . . . . . . . ENGINE COOLANT REPLACEMENT 1. . . . . . . . Wrap a thick cloth around it and slowly turn it counterclockwise to the first stop. . . 0. 5. Even then. . . . . . . . . . . . . . . Remove the radiator cap and loosen the radiator drain plug. . . . .88 Imp qt}/min. RADIATOR CAP INSPECTION . . . . E–4 E–4/5 E–5 E–6 E–6 E–7 E–7 E–7 ENGINE COOLANT Warning D Removing the radiator cap or loosening the radiator drain plug while the engine is running. [max] CONTINUED E–1 . press down on the cap –still using a cloth– turn it. . . .

TO. run it at approx. Pressure F2: 103 kPa {1.040 1.INDEX ENGINE COOLANT Caution D Applying more than 103 kPa {1. Antifreeze solution mixture percentage Volume percentage Coolant protection Water Above –16°C {3°F} Above –26°C {–15°F} Above –40°C {–40°F} 65 55 45 Coolant 35 45 55 Gravity at 20°C {68°F} 1. 17. 9.050 COOLANT PROTECTION 49 9200 146 5.054 1.100 1. 10. 49 9200 147 50% 40% 30% 1. (Refer to ENGINE COOLANT.9 psi} (F2) or 122 kPa {1. Stop the engine and wait until it is cool. MANUAL TO. 14. 14. 10 minutes. If it is low. ENGINE COOLANT LEAKAGE INSPECTION 1.7 psi} CONTINUED E–2 . 17. 3. Apply pressure to the radiator. WL. Inspect the coolant level.000 rpm for five seconds. and other components. Fully install the radiator cap. ENGINE COOLANT LEVEL INSPECTION. WL Turbo: 122 kPa {1. 3.500 rpm for five minutes.020 1. WL Turbo) can damage the hoses.REPAIR MANUAL PAGES.066 1. 4.DRFT. Start the engine and let it idle for approx. If not. Increase the engine speed to approx. Inspect for coolant leakage. If the coolant temperature becomes too high. 13.CHAPTER.25 kgf/cm2. and cause leakage. Fill the coolant into the reservoir up to the FULL mark. Connect a radiator cap tester and the SST to the radiator filler neck. repeat Steps 7—12. FROM.070 1. MODEL . 12.078 8. Verify that the pressure is held. WL. After the engine warms up. Repeat several times.060 1. Remove the radiator cap. 14. 11.030 1. Inspect the coolant level.000 0 –10 0 10 20 30 40 50 60 70 80 90 { 14 } { 32 } { 50 } { 68 } { 86 } { 104 }{ 122 } { 140 } { 158 } { 176 } { 194 } COOLANT TEMPERATURE °C { °F } SPECIFIC GRAVITY 1.9 psi} G6.BACK.25 kgf/cm2.05 kgf/cm2. fittings.) 2. stop the engine to prevent it from overheating.080 1.INDEX RANG.010 1. inspect the system for coolant leakage.7 psi} (G6. 15. then return to idle.090 1.05 kgf/cm2. 2.

RADIATOR RADIATOR CAP RADIATOR CAP INSPECTION Warning D Removing the radiator cap while the engine is running.5—95. If the pressure is held for 10 seconds.7.95—1.8—2. (Refer to ENGINE COOLANT. It may also damage the engine and cooling system.) 2. MANUAL TO. Apply pressure gradually. Even then. 69. the radiator cap is normal. Drain the engine coolant.5—17.25 kgf/cm2. (Refer to ENGINE COOLANT. and remove it. Step back while the pressure escapes. or when the engine and radiator are hot is dangerous. Wrap a thick cloth around it and slowly turn it counterclockwise to the first stop. 14—19} 18—26 {1. 10. press down on the cap –still using a cloth– turn it.9 psi} G6.7—14.8—2.) 7.BACK. Scalding coolant and steam may shoot out and cause serious injury.4 in·lbf} 18—26 {1. D When you’re sure all the pressure is gone.7 N·m {80—110 kgf·cm. 4.DRFT. ft·lbf} 1 2 3 4 Radiator hose Lower radiator cowling Radiator cowling Radiator CONTINUED ST E–3 . MODEL . ENGINE COOLANT REPLACEMENT. 3. WL Turbo: 94—122 kPa {0. WL. Fill the radiator with the specified amount and type of engine coolant.TO. Remove in the order indiacted in the table.9—10.05 kgf/cm2. 1. Verify that the pressure becomes stable within the specification. D Turn off the engine and wait until it is cool. Install in the reverse order of removal.INDEX RANG. Pressure F2: 74—102 kPa {0.7. 2. 49 9200 147 RADIATOR RADIATOR REMOVAL/INSTALLATION 1. 13. 14—19} N·m {kgf·m.75—1.REPAIR MANUAL PAGES.INDEX RADIATOR CAP.7 psi} 3. Attach the radiator cap to a radiator cap tester with the SST.CHAPTER. ENGINE COOLANT REPLACEMENT. be very careful when removing the cap. FROM.

6. ENGINE COOLANT REPLACEMENT.9—2. Install the thermostat into the cylinder head with the jiggle pin at the top.INDEX THERMOSTAT THERMOSTAT 1 2 Upper radiator hose Thermostat cover THERMOSTAT REMOVAL/INSTALLATION 3 Thermostat 1.9—2. ft·lbf} Dipstick pipe Lower radiator hose Thermostat cover Thermostat + Installation Note 2 3 4 1 2 3 Upper radiator hose Thermostat cover Thermostat + Installation Note G6 Thermostat Installation Note F2.6.5—95. G6 1. WL TURBO 4. ENGINE COOLANT REPLACEMENT.9—2.TO. aligning the projection on the gasket to the thermostat cover as shown.6. MODEL . Remove in the order indicated in the table.BACK. FROM.9—2.INDEX RANG. 14—18} R 19—25 {1.4 in·lbf} R 19—25 {1. N·m {kgf·m.6. 3. 14—18} N·m {kgf·m.7 N·m {80—110 kgf·cm. ft·lbf} CONTINUED E–4 . 2. Drain the engine coolant.DRFT.) 2. 14—18} PRINT WL.9—10.) F2 7.CHAPTER.REPAIR MANUAL PAGES. WL. Install a new gasket with the seal print side facing the cylinder head. MANUAL TO. ft·lbf} 1 N·m {kgf·m. (Refer to ENGINE COOLANT. Fill the radiator with the specified amount and type of engine coolant. JIGGLE PIN A 19—25 {1. Install in the reverse order of removal. WL Turbo D Install the thermostat into the thermostat cover. (Refer to ENGINE + Installation Note COOLANT. 69. 14—18} R A–A A 19—25 {1.

WL. WL Turbo : 95 °C {203 °F} Full open lift G6 : 8.06 in} min. (Main valve) 1.CHAPTER. G6 : 100 °C {212 °F} WL.DRFT. MODEL .33 in} min.5 °C {183—187 °F} (Sub valve) WL.0 mm {0. CONTINUED ST E–5 .5—89. Do not touch the thermostat and water directly. MANUAL TO.5 °C {188—193 °F} (Main valve) 83.5—89. FROM. D Open valve in room temperature D Opening temperature and lift of the valve Initial-opening temperature F2: 83.REPAIR MANUAL PAGES.TO. WL Turbo: 8. (Sub valve) F2. Inspect the thermostat for the following and replace as necessary.BACK.5 mm {0.5 °C {183—193 °F} G6: 86. WL Turbo: 80—84 °C {176—183 °F} Full open temperature F2.5—86.5 mm {0. the thermostat and water are extremely hot and they can badly burn.INDEX RANG.31 in} min.INDEX THERMOSTAT GASKET PROJECTION THERMOSTAT COVER THERMOSTAT INSPECTION Warning D During inspection.

28—38} N·m {kgf·m.9—2. (Refer to COOLING FAN. Remove in the order indicated in the table. TIMING BELT REMOVAL/INSTALLATION. Install in the reverse order of removal. (Refer to ENGINE COOLANT. WL TURBO WATER PUMP REMOVAL/INSTALLATION 1.9—2.9—2. Remove the timing belt (F2). {1. ft·lbf} CONTINUED E–6 . 14—18} 1 2 Water pump Idler R 38—51 {3.BACK. ENGINE COOLANT REPLACEMENT. (Refer to ENGINE COOLANT. TIMING BELT. FROM. 6.3.) 19—25 2.6.8—5. ENGINE COOLANT REPLACEMENT.INDEX WATER PUMP WATER PUMP WL.) 3.9—2. 5. Drain the engine coolant. 14—18} (Refer to Section B2.3.2.TO. 14—16} N·m {kgf·m. MODEL . COOLING FAN REMOVAL/INSTALLATION. ft·lbf} 19—25 {1. ft·lbf} G6 R 19—22 {1.) F2 R 19—22 {1. 14—16} N·m {kgf·m.INDEX RANG.DRFT. MANUAL TO.) 4.6.REPAIR MANUAL PAGES.CHAPTER. Remove the cooling fan. Fill the radiator with the specified amount and type of engine coolant.

) CONTINUED E–7 . Install in the reverse order of removal.TO.) F2.9—2.5—95.6. G6: 7. DRIVE BELT ADJUSTMENT. MODEL . FROM.DRIVE BELT. (Refer to Section B2. ft·lbf} 1 2 Cooling fan Water pump pulley COOLING FAN INSPECTION 1. 4. Remove the drive belt. COOLING FAN REMOVAL/INSTALLATION.7 N·m {80—110 kgf·cm.INDEX RANG. 3.BACK. WL TURBO: 19—25 {1. MANUAL TO.4 in·lbf} WL. Replace the cooling fan if necessary.DRFT. Rotate the cooling fan by hand and inspect for abnormal noise and looseness. (Refer to COOLING FAN. Adjust the drive belt (generator) deflection. Remove in the order indicated in the table. 69. 14—18} N·m {kgf·m.INDEX COOLING FAN COOLING FAN COOLING FAN REMOVAL/INSTALLATION 1.CHAPTER. 2.9—10.REPAIR MANUAL PAGES.

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

......... • A/C switch 4.......F1-120/127 ENGINE TUNE-UP ENGINE TUNE-UP PREPARATION Using the SSTs (NGS Tester) 1.......... 3.. PID/DATA MONITOR AND RECORD PROCEDURE.... Shift the transmission into neutral..... Access RPM PID. ENGINE TUNEUP PREPARATION....................... Perform "ENGINE TUNE-UP PREPARATION".F1-70 QUICK DIAGNOSTIC CHART ....DRFT. 1 cylinder......F1-115/120 ENGINE SYSTEM INSPECTION ............................ Turn off all electrical loads........CHAPTER..... Shift the transmission into neutral..............) 4... ON-BOARD DIAGNOSTIC TEST........ F1-52/69 TROUBLESHOOTING . Specification 730—770 (750 ±20) rpm 3.........BACK......F1-70 FOREWORD ........ Caution • Connecting the wrong DLC terminals may possibly cause a malfunction.... IGNITION TIMING ADJUSTMENT Using the SSTs (NGS Tester) 1. Warm up the engine to normal operating temperature........ Specification BTDC 4°—6°(5° ± 1°) CONTINUED F1-2 ...... MODEL .. (Refer to ON-BOARD DIAGNOSTIC SYSTEM..........................F1-71/74 SYMPTOM TROUBLESHOOTING .. F1-48 PLAYBACK OF STORED PIDS PROCEDURE ............ 5............F1-75/114 DIAGNOSTIC INSPECTION. 3..... (Refer to ENGINE TUNE-UP... 5. (Refer to ON-BOARD DIAGNOSTIC SYSTEM....) Not Using the SSTs (NGS tester) 1. Press the trigger key to enter this selection....) 2........... Connect the timing light to the high-tension lead of the No..... Turn off all electrical loads. Connect a dwell tachometer to the DLC terminal IG-.. Verify that the RPM PID is within the specification. If not as specified... F1-51 DTC INSPECTION .. • A/C switch 4...... Press SETUP (Key 8) and turn the test mode on............. Carefully connect the specified terminals only.. MANUAL TO.......... Press CANCEL............... Verify that the timing mark on the crankshaft pulley is within the specification.............. NGS Tester Hook-up Procedure..................... F1-49 SIMULATION TEST PROCEDURE ................... 5......... F1-50/51 AFTER REPAIR PROCEDURE . 6.... adjust the idle speed.. Verify that the steering wheel is at straight ahead position.......TO..................INDEX RANG.......REPAIR MANUAL PAGES. 8..... IDLE SPEED ADJUSTMENT................ Verify that the steering wheel is at straight ahead position..... 9......... FROM.... F1-48/49 DIAGNOSTIC SUPPORT PROCEDURE .....INDEX FUEL AND EMISSION CONTROL SYSTEMS (G6 ) Page 2 of 2 PID/DATA MONITOR AND RECORD PROCEDURE ... 2..... Warm up the engine to normal operating temperature......) 7....... (Refer to ENGINE TUNE-UP.. Press START............... 2..F1-70 TROUBLESHOOTING ITEM TABLE ....... Connect the SSTs (NQS tester) to the DLC and select "PID/DATA MONITOR AND RECORD"........

lbf} 10. perform the following: (1) Connect the SST to the DLC. 9.) 2. Verify that the timing mark on the crankshaft pulley is within the specification. MANUAL TO.9—2. Tightening torque 19—25 N. 14—18 ft. Verify that the idle speed is within the specification. perform the following: Caution • Connecting the wrong DLC terminals may possibly cause a malfunction. If not as specified. 9. adjust the idle speed. loosen the distributor lock bolts and turn the distributor to make the adjustment. 10. MODEL .REPAIR MANUAL PAGES.m. (3) Set the test switch to SELF TEST.m. CONTINUED F1-3 . 4. Disconnect the SST or jumper wire. 14—18 ft.m {1.DRFT.CHAPTER. ENGINE TUNE-UP PREPARATION.BACK. 11. Press CANCEL. • Use a jumper wire to short terminal TEN of the DLC to body GND. If not as specified. Specification BTDC 4°—6° (5° ± 1°) 8. loosen the distributor lock bolts and turn the distributor to make the adjustment.m {1. Carefully connect the specified terminals only. Tightening torque 19—25 N. Tighten the distributor lock bolts to the specified torque. If using the SST (System selector) to turn on the test mode.TO.INDEX RANG.lbf} 8.6 kgf. IDLE SPEED ADJUSTMENT. 7. Tighten the distributor lock bolts to the specified torque. (2) Set switch A to position 1. Specification BTDC 1°—30° 3. Specification BTDC 1°—30° Not Using the SSTs (NGS Tester) 1. Verify that the timing mark on the crankshaft pulley is within the specification. (Refer to ENGINE TUNE-UP. 7. (Refer to ENGINE TUNE-UP.6 kgf. Press SETUP (Key 8) and turn the test mode off.INDEX ENGINE TUNE-UP 6. FROM. If not as specified. Specification 730—770 (750 ± 20) RPM 5. Connect the timing light to the high-tension lead of the No.1 cylinder. Perform "ENGINE TUNE-UP PREPARATION". If using a jumper wire to turn on the test mode.9—2.) 6. Verify that the timing mark on the crankshaft pulley is within the specification.

3. Press SETUP (Key 8) to turn the test mode off. Perform "ENGINE TUNE-UP PREPARATION". MODEL . Caution • Connecting the wrong DLC terminals may possibly cause a malfunction. (Refer to ENGINE TUNE-UP. Press CANCEL.CHAPTER. If using a jumper wire to turn on the test mode. CONTINUED F1-4 . ENGINE TUNE-UP PREPARATION. then adjust the idle speed by turning the AAS. 4. MANUAL TO. If not as specified. Perform "ENGINE TUNE-UP PREPARATION".DRFT. ENGINE TUNE-UP PREPARATION. Verify that the idle speed is normal. ENGINE TUNE-UP PREPARATION. 7. Not Using the SSTs (NGS Tester) 1. 3. Verify that the RPM PID is within the specification. Specification 730—770 (750 ± 20) RPM Caution • The TAS is set at the factory and must not be adjusted. 5. Press CLEAR to clear previously selected items. FROM. • Use a jumper wire to short terminal TEN of the DLC to body GND. perform the following: (1) Connect the SST to the DLC. (Refer to ENGINE TUNE-UP.TO. Press START.REPAIR MANUAL PAGES. Disconnect the SSTs. 4. Disconnect the dwell tachometer. 4.) 2. verify that the ignition timing is within specification according to the "IGNITION TIMING ADJUSTMENT". perform the following: 6. (Refer to ENGINE TUNE-UP.BACK. Verify that the RPM PID is within the specification. (3) Set the test switch to SELF TEST.) 2. IDLE-UP SPEED INSPECTION Using the SSTs (NGS Tester) 1.) 6. If not as specified. Specification 730—770 (750 ± 20) RPM Caution • The TAS is set at the factory and must not be adjusted.INDEX RANG. Perform "ENGINE TUNE-UP PREPARATION". Press SETUP (Key 8) and turn the test mode off. Verify that the idle speed is within the specification using the dwell tachometer. 3. (2) Set switch A to position 1.) 2. If using the SST (System selector) to turn on the test mode. Any adjustment will negatively affect the engine performance. then adjust the idle speed by turning the AAS. verify that the ignition timing is within specification according to the "IGNITION TIMING ADJUSTMENT'. 5. Disconnect the SST or a jumper wire. 5.INDEX ENGINE TUNE-UP IDLE SPEED ADJUSTMENT Using the SSTs (NGS Tester) 1. Any adjustment will negatively affect the engine performance. 6. (Refer to ENGINE TUNE-UP. Carefully connect the specified terminals only. IDLE SPEED ADJUSTMENT.

If not as specified with some load condition. ENGINE SYSTEM. 2 * : Steering wheel is fully turned. Turn the test mode off. 7. 7.) 3. ENGINE SYSTEM INSPECTION. ENGINE SYSTEM INSPECTION. 6.REPAIR MANUAL PAGES. 2. Intake Manifold Vacuum Inspection. inspect the following: • On-board diagnostic system (Refer to ON-BOARD DIAGNOSTIC SYSTEM. 5.) (Refer to ENGINE TUNE-UP.) 3. Specification 1 Load condition Idle-up speed (rpm)* P/S ON*2 700—800 (750 ± 50) A/C ON*3 1 * : Excludes temporary idle speed drop just after the electrical loads (E/L) are turned on. harnesses. 3 minutes. and connectors.) • O2S (Refer to CONTROL SYSTEM. harnesses. If not within the regulation. ENGINE TUNE-UP PREPARATION. Fuel Line Pressure Inspection. 5. 8. IGNITION TIMING INSPECTION. 2 * : Steering wheel is fully turned. IDLE MIXTURE INSPECTION Vehicles With Oxygen Sensor (O2S) 1. IDLE SPEED ADJUSTMENT. VARIABLE RESISTOR INSPECTION. Verify that the idle-up speed is within the specification.) If the systems and devices are normal. (Refer to ENGINE TUNE-UP. ENGINE TUNE-UP PREPARATION.) F1-5 CONTINUED . Intake Manifold Vacuum Inspection. inspect the IAC valve. Verify that the CO and HC concentrations are within the regulation.DRFT.CHAPTER. inspect the following: • On-board diagnostic system (Refer to ON-BOARD DIAGNOSTIC SYSTEM. Ignition Timing Control Inspection. (Refer to ENGINE TUNE-UP. Verify that the CO and HC concentrations are within the regulation. ON-BOARD DIAGNOSTIC TROUBLE CODE INSPECTION. EXHAUST SYSTEM REMOVAL/INSTALLATION. replace the TWC. : A/C switch and fan switch are on.) Vehicles Without Oxygen Sensor O2S) 1.) Ignition timing control (Refer to TROUBLESHOOTING.TO. 4.) 2. turn the adjust screw to adjust CO and HC concentration using the SST. (Refer to IGNITION TIMING INSPECTION. 5. OXYGEN SENSOR O2S) INSPECTION. Perform "ENGINE TUNE-UP PREPARATION". 3 * : A/C switch and fan switch are on. If not as specified with some load conditions. 4. INSPECTION. Not Using the SSTs (NGS Tester) 1. Verify that the idle speed and ignition timing are within the specification. If not. If not as specified with all load conditions.) • Fuel line pressure (Refer to TROUBLESHOOTING. Perform "ENGINE TUNE-UP PREPARATION". Verify that the idle speed is normal. Perform "ENGINE TUNE-UP PREPARATION".) 2.) • Variable resistor (Refer to CONTROL SYSTEM. MODEL . IDLE SPEED ADJUSTMENT.) (Refer to IDLE SPEED ADJUSTMENT.) 3.) • • • Intake manifold vacuum (Refer to TROUBLESHOOTING. Insert an exhaust gas analyzer to the tailpipe. Warm up the engine by holding the engine speed at 2500—3000 rpm for approx. If not as specified with all load conditions. Ignition Timing Control Inspection.) Fuel line pressure (Refer to TROUBLESHOOTING. and connectors. inspect the related input switches. ENGINE SYSTEM INSPECTION.BACK. 4. Fuel line Pressure Inspection. (Refer to ENGINE TUNE-UP. (Refer to ENGINE TUNE-UP. Verify that the idle speed and ignition timing are within the specification. FROM. inspect the related input switches. ENGINE SYSTEM INSPECTION. 6. ENGINE SYSTEM INSPECTION. MANUAL TO.) • Intake manifold vacuum (Refer to TROUBLESHOOTING.) • Ignition timing control (Refer to TROUBLESHOOTING. ON-BOARD DIAGNOSTIC TROUBLE CODE INSPECTION. If not adjusted. Insert an exhaust gas analyzer to the tailpipe. inspect the IAC valve.INDEX RANG. (Refer to EXHAUST SYSTEM.INDEX ENGINE TUNE-UP Specification Load condition P/S ON*2 A/C ON*3 1 Idle-up speed (RPM)*1 700—800 (750 ± 50) • * : Excludes temporary idle speed drop just after the electrical loads (E/L) are turned on.

(Refer to FUEL SYSTEM. they can badly burn. Complete the "AFTER REPAIR PROCEDURE". 4.DRFT. BEFORE REPAIR PROCEDURE. Fuel can also irritate skin and eyes.) 3. AFTER REPAIR PROCEDURE. 5. MODEL . Remove in the order indicated in the table. (Refer to Section E.) (Refer to FUEL SYSTEM. Fuel can ignite and cause serious injuries or death and damage. ENGINE COOLANT. • Fuel vapor is hazardous.) 1.TO. always complete the following "Fuel Line Safety Procedures".) CONTINUED F1-6 . Disconnect the negative battery cable. (Refer to FUEL SYSTEM. MANUAL TO. Complete the "BEFORE REPAIR PROCEDURE". Drain the engine coolant from the radiator.CHAPTER. Install in the reverse order of removal. 6. Turn off engine and wait until they are cool before removing the intake-air system. BEFORE REPAIR PROCEDURE. FROM.INDEX RANG. ENGINE COOLANT REPLACEMENT. causing serious injury and damage.) 2. (Refer to FUEL SYSTEM. It can easily ignite. • Fuel line spills and leakage are dangerous. AFTER REPAIR PROCEDURE.REPAIR MANUAL PAGES. Always keep sparks and flames away from fuel. To prevent this.BACK.INDEX INTAKE-AIR SYSTEM INTAKE-AIR SYSTEM VACUUM HOSE ROUTING DIAGRAM INTAKE-AIR SYSTEM REMOVAL/INSTALLATION Warning • When the engine and intake-air system are hot.

MODEL .REPAIR MANUAL PAGES.DRFT. FROM.INDEX RANG.INDEX INTAKE-AIR SYSTEM 1 2 3 4 Air cleaner component Air intake hose MAP sensor Accelerator cable ☞ ACCELERATOR CABLE INSPECTION/ ADJUSTMENT 5 6 7 Throttle body component Dynamic chamber Fuel injector ☞ FUEL SYSTEM.TO. MANUAL TO. FUEL INJECTOR REMOVAL/ INSTALLATION Intake manifold 8 CONTINUED F1-7 .CHAPTER.BACK.

inspect for the following: Open circuit • Power circuit (IAC valve connector terminal A and main relay terminal D) 5. If not as specified. (Refer to TROUBLESHOOTING. Disconnect the IAC valve connector. IDLE AIR CONTROL (IAC) VALVE INSPECTION Resistance Inspection Note 2.) 2. 8. 1. Disconnect the negative battery cable. (Refer to BAC VALVE REMOVAL/INSTALLATION. Repair or replace faulty areas.INDEX RANG. MODEL . 3. Resistance 7. If not as specified. Carry out the "Idle Air Control (IAC) Inspection". Verify that the air valve operates when hot water is added into the engine coolant passage of the BAC valve. 6. Install in the reverse order of removal. perform the further inspection for the IAC valve. (Refer to TROUBLESHOOTING. Disconnect the IAC valve connector. ENGINE SYSTEM INSPECTION. Perform the following test only when directed.CHAPTER.) If as specified. Perform the following test only when directed. ENGINE COOLANT. AIR VALVE INSPECTION Operation Inspection Note 1. 3.) 3. 6. 4. 2. FROM. 9. If not as specified. (Refer to INTAKE-AIR SYSTEM.TO.) 4. Remove the BAC valve. Install the BAC valve. Idle Air Control (IAC) Inspection. Idle Air Control (IAC) Inspection.BACK. Disconnect the negative battery cable. Add cold water into the engine coolant passage of the BAC valve to reduce the air valve temperature.DRFT. Connect the IAC valve connector. Drain the engine coolant from the radiator. 1. Measure the resistance between the IAC valve terminals using an ohmmeter. ENGINE COOLANT REPLACEMENT. Carry out the "Idle Air Control (IAC) Inspection".) 2. Remove the BAC valve.3 Ω [23 °C {73 °F}] GND circuit (IAC valve connector terminal B and PCM connector terminal 2W) Short circuit • IAC valve connector terminal B and PCM connector terminal 2W to GND 7. 5.REPAIR MANUAL PAGES. • CONTINUED F1-8 . 5. (Refer to section E. Connect the negative battery cable. MANUAL TO. BAC VALVE REMOVAL/INSTALLATION. ENGINE SYSTEM INSPECTION. replace the BAC valve.7—9. replace the BAC valve. 4.INDEX INTAKE-AIR SYSTEM BYPASS AIR CONTROL (BAC) VALVE REMOVAL/INSTALLATION 1. but IAC valve is failed.

Remove in the order indicated in the table.REPAIR MANUAL PAGES. If not as specified.CHAPTER. MANUAL TO.11 in} 2. adjust by turning the locknut. 1 2 Accelerator cable ☞ ACCELERATOR CABLE INSPECTION/ADJUSTMENT Accelerator pedal ACCELERATOR CABLE INSPECTION/ADJUSTMENT 1. CONTINUED F1-9 . FROM.INDEX RANG. Free play 1—3 mm {0. Measure the free play of the accelerator cable. MODEL .04—0.INDEX INTAKE-AIR SYSTEM ACCELERATOR PEDAL REMOVAL/INSTALLATION 1.BACK. Install in the reverse order of removal.TO. 2.DRFT.

Caution • Connecting the wrong DLC terminal may possibly cause a malfunction. Fuel can ignite and cause serious injuries or death and damage. To prevent this. 2. After repair. Short the DLC terminal F/P to body GND using a jumper wire. fit the hose onto the pipe over 25 mm {0. observe "Fuel Hose Installation" and "Fuel Leakage Inspection" described below. 4. Fuel Hose Installation 1.BACK. When installing the fuel hose onto the fuel pipe. and fuel pipe sealing surface and replace as necessary. MANUAL TO. 5. Note • Fuel in the fuel system is under high pressure when the engine is not running. Always carry out the following procedure with the engine stopped. Turn the ignition switch on to operate the fuel pump body. CLAMP INSTALLATION RANGE 3. If there is fuel leakage.INDEX FUEL SYSTEM FUEL SYSTEM BEFORE REPAIR PROCEDURE Warning • Fuel vapor is hazardous.DRFT. • Fuel line spills and leakage are dangerous. AFTER REPAIR PROCEDURE Warning • Fuel line spills and leakage are dangerous. Pressurize the system this way for at least 5 minutes to be sure of no leakage. Turn off the ignition switch. 4. Fuel can ignite and cause serious injuries or death and damage. hose clamps. always complete the following "Fuel Line Safety Procedures". Remove the fuel-filler cap and release the pressure in the fuel tank. 6. avoiding the original clamp position. Start the engine. It can easily ignite. When the pipe has a stopper.INDEX RANG. Fuel Line Safety Procedures 1. fit the hose until it contacts the stopper.CHAPTER.REPAIR MANUAL PAGES.TO. Fuel Leakage Inspection Warning • Fuel line spills and leakage are dangerous. Carefully connect the specified terminal only. Always keep sparks and flames away from fuel. fuel pipes. 3. Reconnect the fuel pump relay connector. Fuel can also irritate skin and eyes. 5. Fuel can ignite and cause serious injuries or death and damage. Install a hose clamp over the fuel hose within the clamp installation range as shown. 1. causing serious injury and damage. MODEL . crank the engine several times. Disconnect the fuel pump relay connector located under the passenger's side front side trim. 2. assemble the system and repeat Steps 1 to 3. 2. After the engine stalls. inspect for damaged fuel hoses. F1-10 CONTINUED . When installing the fuel hose. FROM.98 in}. Replace damaged or deformed fuel hoses. and hose clamps. 3.

INDEX FUEL SYSTEM FUEL TANK REMOVAL/INSTALLATION Warning • Repairing a fuel tank that has not been properly steam cleaned can be dangerous. Complete the "BEFORE REPAIR PROCEDURE". do not damage the sealing surface of the fuel pump unit when removing or installing.) STRETCH CAB 2WD. Drain the fuel from the drain plug. FROM.BACK. (Refer to FUEL SYSTEM. MODEL . Complete the "AFTER REPAIR PROCEDURE". MANUAL TO.CHAPTER. Remove in the order indicated in the table.DRFT. Install in the reverse order of removal. Disconnect the negative battery cable. 6. Always properly steam clean a fuel tank before repairing it. • Fuel line spills and leakage are dangerous. 1.REPAIR MANUAL PAGES. Level the vehicle.TO. 5. 7. AFTER REPAIR PROCEDURE. To prevent this.) 3.INDEX RANG. Fuel can ignite and cause serious injuries or death and damage. DOUBLE CAB 2WD CONTINUED F1-11 . BEFORE REPAIR PROCEDURE. Fuel can also irritate skin and eyes. 4. (Refer to FUEL SYSTEM. Explosion or fire may cause death or serious injury. 2.

MODEL .BACK. REGULAR CAB 1 2 3 4 5 6 7 Joint hose ☞ Installation Note Breather hose ☞ Installation Note Under guard Fuel hose Fuel tank Evaporative hose ☞ Installation Note Rollover valve 8 Fuel pump unit 9 Fuel-filler pipe 10 Dust cover 11 Fuel inlet pipe 12 Nonreturn valve 13 Evaporative gas check valve (two-way) ☞ Installation Note 14 Check valve (two-way) 15 Evaporative chamber CONTINUED F1-12 . FROM.INDEX RANG.TO. MANUAL TO.REPAIR MANUAL PAGES.CHAPTER.DRFT.INDEX FUEL SYSTEM STRETCH CAB 4WD. DOUBLE CAB 4WD.

1.INDEX FUEL SYSTEM Evaporative Gas Check Valve (Two-way) Installation Note • Install the arrow mark of the evaporative gas check valve (two-way) facing the charcoal canister. (Refer to FUEL SYSTEM.FUEL TANK REMOVAL/INSTALLATION.DRFT. MODEL .) 2.) FUEL PUMP UNIT DISASSEMBLY/ASSEMBLY Warning • Fuel line spills and leakage are dangerous.FUEL TANK REMOVAL/INSTALLATION. FUEL PUMP UNIT REMOVAL/INSTALLATION 1. If not as specified.TO. 2. Install the fuel pump unit. Assemble in the reverse order of disassembly. Fuel can also irritate skin and eyes. (Refer to FUEL SYSTEM. CONTINUED F1-13 . Disassemble in the order indicated in the table.5 mm {0. Length Evaporative hose: 25—30 mm {0.REPAIR MANUAL PAGES.4—1.CHAPTER.18 in} NONRETURN VALVE INSPECTION 1. 2. Joint Hose Installation Note • Fit the joint hose onto the respective fittings within the specification. and install clamps as shown. Remove the fuel pump unit. Remove the nonreturn valve with the fuel inlet pipe. Evaporative Hose Installation Note • Fit each hose onto the respective fittings within the specification. and install clamp as shown. Verify that the nonreturn valve opening angle is 50—56° when pushed out from the fuel inlet pipe side. do not damage the sealing surface of the fuel pump unit when removing or installing.INDEX RANG. and install clamps as shown.06 in} when the nonreturn valve is returned to the closed position.5 in} 3. FROM. Length Joint hose: 35—40 mm {1.18 in} Breather Hose Installation Note • Fit each hose onto the respective fittings within the specification. replace the nonreturn valve. Fuel can ignite and cause serious injuries or death and damage. MANUAL TO. Length Breather hose: 25—30 mm {0. To prevent this.99—1.99—1.BACK. and the clearance between the nonreturn valve and the fuel inlet pipe end is within 1.

(Refer to FUEL SYSTEM. Reconnect the negative battery cable.) (Refer to TROUBLESHOOTING. Disconnect the negative battery cable.REPAIR MANUAL PAGES. Remove the fuel tank.) Short circuit • Fuel pump relay connector terminal D and fuel pump unit connector terminal B through common connector to GND 6. replace the fuel pump body. 3.CHAPTER.INDEX RANG. (Refer to FUEL SYSTEM. Fuel Pump Operation Inspection. Continuity Inspection Note • Perform the following test only when directed. perform the further inspection for the fuel pump unit. 1.) CONTINUED F1-14 . inspect the following: Fuel pump relay malfunction Open circuit • GND circuit (fuel pump unit connector terminal D and body GND) • Power circuit (fuel pump relay connector terminal D and fuel pump unit connector terminal B through common connector) 1 2 3 4 5 6 Rubber mount Fuel filter (low-pressure) Clamp Fuel hose Fuel pump body Fuel gauge sender unit FUEL PUMP UNIT INSPECTION Simulation Test 1. DOUBLE CAB 2WD 2. If as specified but the "Simulation Test" is failed. "Fuel Pump Control Inspection". BEFORE REPAIR PROCEDURE. Fuel Pump Control Inspection. 7. Complete the "BEFORE REPAIR PROCEDURE".) 8. Repair or replace faulty areas. AFTER REPAIR PROCEDURE. ENGINE SYSTEM INSPECTION. REGULAR CAB 5.) 2. ENGINE SYSTEM INSPECTION.INDEX FUEL SYSTEM STRETCH CAB 2WD. Carry out the "Fuel Pump Operation Inspection". 9. STRETCH CAB 4WD. Complete the "AFTER REPAIR PROCEDURE". MODEL . MANUAL TO. FROM. (Refer to TROUBLESHOOTING. Inspect for continuity between fuel pump unit connector terminals C and D. DOUBLE CAB 4WD. Install the fuel tank.DRFT. If not as specified.BACK. FUEL TANK REMOVAL/INSTALLATION. FUEL TANK REMOVAL/INSTALLATION.TO. If there is no continuity.) 4. (Refer to FUEL SYSTEM. (Refer to FUEL SYSTEM.

) Fuel Pump Hold Pressure Inspection Warning • Fuel line spills and leakage are dangerous. Complete the "BEFORE REPAIR PROCEDURE". Short the DLC terminal F/P to body GND using a jumper wire. BEFORE REPAIR PROCEDURE. 12. (Refer to FUEL SYSTEM.INDEX FUEL SYSTEM Fuel Pump Maximum Pressure Inspection Warning • Fuel line spills and leakage are dangerous. MANUAL TO. Note • 1.REPAIR MANUAL PAGES. 3. If not as specified. inspect the following: • Fuel pump relay • Fuel filter (low-pressure.0—6. (Refer to FUEL SYSTEM. Caution • Connecting the wrong DLC terminal may possibly cause a malfunction. • Connecting the wrong DLC terminal may possibly cause a malfunction. Connect the negative battery cable. 8. 5. Perform the following test only when directed. Fuel can ignite and cause serious injuries or death and damage. MODEL . Carefully connect the specified terminal only.INDEX RANG. (Refer to FUEL SYSTEM. Fuel can ignite and cause serious injuries or death and damage. Turn the ignition switch on to operate the fuel pump body. CONTINUED F1-15 . Disconnect the negative battery cable. Complete the "AFTER REPAIR PROCEDURE". (Refer to FUEL SYSTEM. Disconnect the negative battery cable. high-pressure) for clogging • Fuel line for clogging or leakage 9. Fuel pump maximum pressure 500—630 kPa {5. Note • 1. 72—92 psi} 7. 2. 13. Carefully connect the specified terminal only. then plug the opening as shown. FROM. BEFORE REPAIR PROCEDURE. Disconnect the negative battery cable. Always carry out the following procedure with the engine stopped. Complete the "BEFORE REPAIR PROCEDURE". Perform the following test only when directed.CHAPTER.TO. Caution 6.) 2. Connect a fuel pressure gauge to the fuel hose between the pulsation damper and fuel main hose. Measure the fuel pump maximum pressure. AFTER REPAIR PROCEDURE. 11. Always carry out the following procedure with the engine stopped.) 10. Short the DLC terminal F/P to body GND using a jumper wire.BACK. Disconnect the fuel pressure gauge. Connect a fuel pressure gauge to the fuel hose between the pulsation damper and fuel main hose.5 kgf/cm2. 5. Turn the ignition switch off and disconnect the jumper wire. BEFORE REPAIR PROCEDURE. Connect the negative battery cable.) 4. Connect the negative battery cable. Complete the "BEFORE REPAIR PROCEDURE". 4. 3. then plug the opening as shown.DRFT.

paint marks on the fuel filter (high-pressure) and fuel filter bracket for correct reassembly. Paint a mark on the new fuel filter (high-pressure) at the same spot as the removed fuel filter (highpressure). 9. AFTER REPAIR PROCEDURE. Turn the ignition switch on for 10 seconds to operate the fuel pump body. Remove in the order indicated in the table. If not as specified. Complete the "BEFORE REPAIR PROCEDURE". Fuel Filter (High-pressure) Installation Note Replacing the fuel filter (high-pressure) 1. Disconnect the fuel pressure gauge. 3. Turn the ignition switch off. MANUAL TO. Measure the fuel pump hold pressure after 5 minutes. FUEL INJECTOR INSPECTION. 7.TO. 4. AFTER REPAIR PROCEDURE. Fuel pump hold pressure More than 340 kPa {3. 13. PRESSURE REGULATOR INSPECTION. 11. (Refer to FUEL SYSTEM. 5. MODEL . "FUEL INJECTOR INSPECTION" (Refer to FUEL SYSTEM.INDEX RANG. CONTINUED F1-16 . Reconnect the negative battery cable.CHAPTER.) (Refer to FUEL SYSTEM. carry out the "PRESSURE REGULATOR INSPECTION". 2. Complete the "AFTER REPAIR PROCEDURE". Disconnect the jumper wire.5 kgf/cm2. Disconnect the negative battery cable. Complete the "AFTER REPAIR PROCEDURE". Disconnect the negative battery cable. Complete the "BEFORE REPAIR PROCEDURE". (Refer to FUEL SYSTEM. 50 psi} 8.) FUEL FILTER (HIGH-PRESSURE) REMOVAL/INSTALLATION 1.) 2.REPAIR MANUAL PAGES.BACK.) 14.) 10. 12. Install in the reverse order or removal. (Refer to FUEL SYSTEM.INDEX FUEL SYSTEM 6.) 1 2 3 Fuel hose Protector Fuel filter (high-pressure) ☞ Removal Note ☞ Installation Note Fuel Filter (High-pressure) Removal Note • Before removing the fuel filter (high-pressure). BEFORE REPAIR PROCEDURE. BEFORE REPAIR PROCEDURE.DRFT. Align the paint marks and install the fuel filter (high-pressure) as shown. FROM. (Refer to FUEL SYSTEM.

REPAIR MANUAL PAGES.TO. 2. Paint a mark on the new fuel filter bracket at the same spot as the removed fuel filter bracket.INDEX FUEL SYSTEM Replacing the fuel filter bracket 1.DRFT.CHAPTER.BACK. CONTINUED F1-17 . MANUAL TO. FROM. MODEL . Align the paint marks and install the fuel filter bracket as shown.INDEX RANG.

Complete the "BEFORE REPAIR PROCEDURE" (Refer to FUEL SYSTEM.REPAIR MANUAL PAGES. 4. Complete the "AFTER REPAIR PROCEDURE. 6.INDEX FUEL SYSTEM FUEL INJECTOR REMOVAL/INSTALLATION Warning • Fuel line spills and leakage are dangerous. To prevent this. 3. Remove in the order indicated in the table. BEFORE REPAIR PROCEDURE. always complete the "Fuel Line Safety Procedures".DRFT. Disconnect the fuel injector connectors and remove the harness from the fuel distributor.) 1.) 1 Dynamic chamber 2 Dynamic chamber gasket 3 Fuel injector connector 4 Fuel hose 5 Fuel distributor 6 Fuel injector ☞ Installation note 7 Grommet 8 Fuel injector insulator CONTINUED F1-18 . 5.) Disconnect the negative battery cable. Fuel can also irritate skin and eyes.CHAPTER. MANUAL TO.BACK. Install in the reverse order of removal. Fuel can ignite and cause serious injuries or death and damage. BEFORE REPAIR PROCEDURE." (Refer to FUEL SYSTEM. 2.INDEX RANG. MODEL . AFTER REPAIR PROCEDURE. (Refer to FUEL SYSTEM. FROM.TO.

If not as specified. Reconnect the negative battery cable. ENGINE SYSTEM INSPECTION.3 cylinder fuel injector connector terminal B and PCM connector terminal 2U to GND • No.3 cylinder fuel injector connector terminal A and main relay connector terminal D through common connector) • Power circuit (No. replace the fuel injector. Always carry out the following procedure with the engine stopped. (Refer to FUEL SYSTEM.) If as specified but "Simulation Test" is failed. Reconnect the fuel injector connectors. CONTINUED F1-19 . Use new fuel injector O-rings. Clean with gasoline if necessary. 2. 1.4 cylinder fuel injector connector terminal B and PCM connector terminal 2V to GND 5. Verify that the O-rings and the fuel injector sealing surfaces are free of foreign materials. Open circuit • GND circuit (No.4 cylinder fuel injector connector terminal A and main relay connector terminal D through common connector) FUEL INJECTOR INSPECTION Simulation Test 1. Fuel Injector Operation Inspection. Fuel can ignite and cause serious injuries or death and damage.CHAPTER. inspect for the following: Short circuit • No. Apply a small amount of engine oil to the O-rings and into the fuel distributor. Disconnect the negative battery cable.BACK. 4. Resistance Inspection Note • Perform the following test only when directed. Carry out the "Fuel Injector Operation Inspection".2 cylinder fuel injector connector terminal B and PCM connector terminal 2V) • GND circuit (No. (Refer to TROUBLESHOOTING. FUEL INJECTOR REMOVAL/INSTALLATION.4 cylinder fuel injector connector terminal B and PCM connector terminal 2V) • Power circuit (No. Resistance 12—16Ω[20°C {68°F}] 4.) 2. Fuel Leakage Test Warning • Fuel line spills and leakage are dangerous. 6. 3. perform the further inspection for the fuel injectors. MANUAL TO. FROM. Disconnect the fuel injector connectors. Measure the resistance of the fuel injector using an ohmmeter. 3. 2. If not as specified.1 cylinder fuel injector connector terminal B and PCM connector terminal 2U to GND • No. 7.3 cylinder fuel injector connector terminal B and PCM connector terminal 2U) • GND circuit (No.2 cylinder fuel injector connector terminal A and main relay connector terminal D through common connector) • Power circuit (No.1 cylinder fuel injector connector terminal B and PCM connector terminal 2U) • GND circuit (No.TO. Note • Perform the following test only when directed.REPAIR MANUAL PAGES.1 cylinder fuel injector connector terminal A and main relay connector terminal D through common connector) • Power circuit (No. Install the fuel injectors in the fuel distributor with a light twisting motion so that the O-rings will not be folded. Repair or replace faulty areas.INDEX RANG.DRFT.INDEX FUEL SYSTEM Fuel Injector Installation Note 1. MODEL .2 cylinder fuel injector connector terminal B and PCM connector terminal 2V to GND • No.

Caution • Connecting the wrong DLC terminal may possibly cause a malfunction. If not as specified. 60 degrees and verify that fuel leakage from the fuel injector nozzles is within the specification.INDEX RANG. Turn the ignition switch on to operate the fuel pump body. 9. Complete the "AFTER REPAIR PROCEDURE". Carefully connect the specified terminal only. (Refer to FUEL SYSTEM. 10.CHAPTER. Tilt the fuel injectors approx. AFTER REPAIR PROCEDURE. 9. 2. Fasten the fuel injectors firmly to the fuel distributor with wire. 5. FUEL INJECTOR REMOVAL/INSTALLATION. (Refer to FUEL SYSTEM. Remove the fuel injectors together with the fuel distributor. Remove the fuel injectors together with the fuel distributor. Disconnect the negative battery cable. Short the DLC terminal F/P to body GND using a jumper wire.TO.) 4. 6. 7. 4. Connect the SST as shown in the figure. 3. 1. BEFORE REPAIR PROCEDURE. 7. Carefully connect the specified terminal only.REPAIR MANUAL PAGES. • 5. MODEL . Always carry out the following procedure with the engine stopped. (Refer to FUEL SYSTEM. Fuel leakage Less than 1 drop/2 minutes 8.DRFT. (Refer to FUEL SYSTEM. MANUAL TO. (Refer to FUEL SYSTEM.) Volume Test Warning Fuel line spills and leakage are dangerous. Short the DLC terminal F/P to body GND using a jumper wire. replace the fuel injector. FUEL INJECTOR REMOVAL/INSTALLATION. F1-20 CONTINUED . 11. BEFORE REPAIR PROCEDURE.BACK. 3.) Disconnect the negative battery cable. 6. Turn the ignition switch off and remove the jumper wire. Connect the negative battery cable. Note • Perform the following test only when directed. 8. Turn the ignition switch on to operate the fuel pump body. Fuel can ignite and cause serious injuries or death and damage. Complete the "BEFORE REPAIR PROCEDURE".) 2. Measure the injection volume of each fuel injector using a graduated container.) Fasten the fuel injectors firmly to the fuel distributor with wire. FROM.INDEX FUEL SYSTEM 1. Complete the "BEFORE REPAIR PROCEDURE". Caution • Connecting the wrong DLC terminal may possibly cause a malfunction. Connect the negative battery cable.

14. always complete the "Fuel Line Safety Procedures". Measure the fuel line pressure after approx. If not as specified.) 1.BACK. Connect a fuel pressure gauge between the pulsation damper and fuel main hose. 2 minutes. Install in the reverse order of removal.1—2. replace the fuel injector. (Refer to FUEL SYSTEM. 11. Start the engine and let it idle. (Refer to FUEL SYSTEM. 10.") 10. 4. Connect the negative battery cable.7—3. If not as specified. Reconnect the fuel main hose to the fuel distributor. Complete the "AFTER REPAIR PROCEDURE". MODEL . Disconnect the negative battery cable. (Refer to FUEL SYSTEM. Operation Inspection Note • Perform the following test only when directed. To prevent this. (Refer to TROUBLESHOOTING.INDEX FUEL SYSTEM Injection volume 55—71 ml {55—71 cc.6 kgf/cm . 1. perform the further inspection for the pressure regulator. 30—36 psi} 7. Remove in the order indicated in the table. ENGINE SYSTEM INSPECTION. BEFORE REPAIR PROCEDURE". 9. Complete the "BEFORE REPAIR PROCEDURE". 5. Complete the "AFTER REPAIR PROCEDURE". Fuel line pressure 2 210—250 kPa {2. BEFORE REPAIR PROCEDURE.DRFT. 12. 3. Disconnect the vacuum hose from the pressure regulator and measure the fuel line pressure. Fuel line pressure 270—310 kPa {2. Disconnect the fuel pressure gauge. (Refer to FUEL SYSTEM. 4. Disconnect the negative battery cable.) 2. (Refer to FUEL SYSTEM. 5. 3. Complete the "BEFORE REPAIR PROCEDURE". If not as specified. FROM. 11. 39—45 psi} 8.) 2. 12.3 fl oz}/15 sec. AFTER REPAIR PROCEDURE. O 1 Vacuum hose 2 Fuel hose 3 Pressure regulator PRESSURE REGULATOR INSPECTION Simulation Test 1.2 kgf/cm2. (Refer to FUEL SYSTEM. BEFORE REPAIR PROCEDURE. AFTER REPAIR PROCEDURE.INDEX RANG. Fuel Line Pressure Inspection. Reconnect the negative battery cable. Disconnect the negative battery cable. Turn the ignition switch off. Complete the "BEFORE REPAIR PROCEDURE". kinks or leakage CONTINUED F1-21 . Carry out the "Fuel Line Pressure Inspection".CHAPTER. Turn the ignition switch off and disconnect the jumper wire. Fuel can ignite and cause serious injuries or death and damage.REPAIR MANUAL PAGES.TO. 13. 6. MANUAL TO. inspect the following: • Fuel pump maximum pressure • Fuel pump hold pressure • Fuel filter for clogging • Fuel injector for leakage • Fuel pump relay • Fuel line for improper routing.9—2. BEFORE REPAIR PROCEDURE. Fuel can also irritate skin and eyes.) 2.) 1.) PRESSURE REGULATOR REMOVAL/INSTALLATION Warning • Fuel line spills and leakage are dangerous. clogging.

Complete the "AFTER REPAIR PROCEDURE".BACK.TO. AFTER REPAIR PROCEDURE.) 3. PULSATION DAMPER REMOVAL/INSTALLATION. inspect for the following: Vacuum hose improper routing. which will cause fuel leakage. VACUUM HOSE ROUTING DIAGRAM.REPAIR MANUAL PAGES. (Refer to FUEL SYSTEM.INDEX FUEL SYSTEM If all items above are okay.CHAPTER. PRESSURE REGULATOR REMOVAL/INSTALLATION. 4. CONTINUED F1-22 . AFTER REPAIR PROCEDURE. Remove the pulsation damper.) 2. replace the pulsation damper. 6. Carry out the "Pressure Regulator Control (PRC) Inspection". PULSATION DAMPER REMOVAL/INSTALLATION 1. MODEL . FROM. (Refer to FUEL SYSTEM.) 1 4. (Refer to FUEL SYSTEM. MANUAL TO. If either is observed. (Refer to TROUBLESHOOTING.) 2. Install in the reverse order of removal. Complete the "BEFORE REPAIR PROCEDURE". 2.) 15. Disconnect the negative battery cable.INDEX RANG. Repair or replace faulty areas. Short circuit • PRC solenoid valve connector terminal B and PCM connector terminal 2T through common connector to GND) 5. Install the PRC solenoid valve. If not as specified. 7. ENGINE SYSTEM INSPECTION. Pressure Regulator Control (PRC) Inspection. kinks or leakage Open circuit • GND circuit (PRC solenoid valve connector terminal B and PCM connector terminal 2T through common connector) • Power circuit (PRC solenoid valve connector terminal A and main relay connector terminal D through common connector) 2 3 Fuel hose Bolt Pulsation damper PULSATION DAMPER INSPECTION 1. Remove the PRC solenoid valve. Visually inspect the pulsation damper for damage and cracks. If not as spec tied. Remove the pulsation damper. (Refer to FUEL SYSTEM. Inspect airflow between the ports under the following conditions. BEFORE REPAIR PROCEDURE. (Refer to INTAKE-AIR SYSTEM. Airflow Inspection Note • Perform the following test only when directed. replace the pressure regulator. 3. replace the PRC solenoid valve. Disconnect the negative battery cable. 1. Reconnect the negative battery cable.) 2.) PRESSURE REGULATOR CONTROL (PRC) SOLENOID VALVE INSPECTION Simulation Test 1.DRFT. 3. (Refer to FUEL SYSTEM. 5. Complete the "AFTER REPAIR PROCEDURE". perform the further inspection for the PRC solenoid valve. Also inspect that there is no extreme rust. If as specified but the "Simulation Test" is failed.

If as specified but the "Simulation Test" is failed.DRFT.CHAPTER. (Refer to TROUBLESHOOTING. 2. • Power circuit (fuel pump relay connector terminal A or C and IG switch connector terminal IG1 through common connector) 3.BACK.INDEX FUEL SYSTEM FUEL PUMP RELAY INSPECTION Simulation Test 1.) 2. ENGINE SYSTEM INSPECTION. Disconnect the negative battery cable.TO. Short circuit • Fuel pump relay connector terminal B and PCM connector terminal 1H through common connector to GND • Fuel pump relay connector terminal D and fuel pump unit connector terminal B through common connector to GND 5. FROM. Reconnect the negative battery cable. Carry out the "Fuel Pump Operation Inspection". Repair or replace faulty areas. 4. ENGINE SYSTEM INSPECTION. replace the fuel pump relay. 1. Remove the fuel pump relay located under the passenger's side front side trim. perform the further inspection for the fuel pump relay. Fuel Pump Operation Inspection. 6. If not as specified.) (Refer to TROUBLESHOOTING. MODEL .REPAIR MANUAL PAGES. inspect for the following: Fuel pump unit malfunction Open circuit • GND circuit (fuel pump relay connector terminal B and PCM connector terminal 1H through common connector) • GND circuit (fuel pump relay connector terminal D and fuel pump unit connector terminal B through common connector) CONTINUED F1-23 . MANUAL TO. "Fuel Pump Control Inspection". If not as specified. 7. Continuity Inspection Note • Perform the following test only when directed. Inspect for continuity between the fuel pump relay terminals using an ohmmeter. Install the fuel pump relay.INDEX RANG. Fuel Pump Control Inspection.

DRFT. repair or replace as necessary. Install in the reverse order of removal. 1 2 3 After silencer Main silencer TWO (Europe) Presilencer (Except Europe) 4 5 6 Front pipe Insulator Exhaust manifold CONTINUED F1-24 .CHAPTER.INDEX EXHAUST SYSTEM EXHAUST SYSTEM EXHAUST SYSTEM INSPECTION 1.REPAIR MANUAL PAGES. Remove in the order indicated in the table. 1.INDEX RANG.TO. MODEL . MANUAL TO. 3. they can badly burn. Start the engine and inspect the exhaust system component for exhaust gas leakage. If leakage is found. FROM. Disconnect the negative battery cable. 2.BACK. 2. EXHAUST SYSTEM REMOVAL/INSTALLATION Warning • When the engine and exhaust system are hot. Turn off the engine and wait until they are cool before removing the exhaust system.

CHAPTER. FUEL TANK REMOVAL/INSTALLATION. Apply pressure below +2.9 kPa {+44 mmHg. Remove the evaporative gas check valve (twoway).) 2. FUEL TANK REMOVAL/INSTALLATION.6 kPa {+140 mmHg.7 kPa {-7. Inspect airflow of the valve under the following conditions.) 2. -0. (Refer to FUEL SYSTEM. EVAPORATIVE GAS CHECK VALVE (TWOWAY) INSPECTION 1. Blow air into port A and verify that there is no airflow.87 inHg} to port A Apply pressure over +5. +5.5 inHg} to port A Apply pressure over -4.4 inHg} to port B 3.8 mmHg.98—1-13. FUEL TANK REMOVAL/INSTALLATION. +1. CHECK VALVE (TWO-WAY) INSPECTION 1. Blow air into port A and verify that there is airflow.REPAIR MANUAL PAGES. Remove the rollover valve. (Refer to FUEL SYSTEM. +0.28— + 4.BACK. No airflow Airflow Airflow CONTINUED F1-25 .TO. Hold the valve as shown. (Refer to FUEL SYSTEM.) 2.9 kPa {+22 mmHg. replace the rollover valve. Remove the check valve (two-way). If not as specified. FROM. Turn the valve upside-down as shown.36 mmHg. Inspect airflow of the valve under the following conditions. MODEL .3—1-102 mmHg. MANUAL TO. replace the evaporative gas check valve (two-way).9 kPa {-36. Apply pressure of -0. If not as specified.98 kPa {-7. 3. -0.INDEX EMISSION SYSTEM EMISSION SYSTEM EMISSION SYSTEM (ENGINE COMPARTMENT SIDE) COMPONENT LOCATION 4.INDEX RANG.DRFT.7 inHg} to port A Apply pressure over -0.0 inHg} to port A Apply pressure over +18.29 inHg} to port A No airflow Airflow Airflow 1 2 3 Charcoal canister Purge solenoid valve PCV valve ROLLOVER VALVE INSPECTION 1. -1.

Plug the atmosphere side port and purge solenoid valve side port of the charcoal canister. If there is air leakage. ENGINE SYSTEM INSPECTION. If not as specified. FROM. FUEL TANK REMOVAL/INSTALLATION. 2. Purge Control Inspection. If as specified but the "Simulation Test" is failed. Carry out the "Purge Control Inspection". Remove the evaporative chamber.) 2. Disconnect the negative battery cable. If not as specified. replace the check valve (twoway). CHARCOAL CANISTER INSPECTION 1. MANUAL TO. Open circuit • GND circuit (purge solenoid valve connector terminal B and PCM connector terminal 2X through common connector) • Power circuit (purge solenoid valve connector terminal A and main relay connector terminal D through common connector) 4. MODEL . inspect for the following: Vacuum hose improper routing. Airflow Inspection Note • Perform the following test only when directed. replace the charcoal canister. If not as specified. Visually inspect that there is no damage nor crack on the evaporative chamber. 2. Inspect airflow between the ports under the following conditions. perform the further inspection for the purge solenoid valve.BACK.REPAIR MANUAL PAGES. replace the evaporative chamber. 3. 4. EVAPORATIVE CHAMBER INSPECTION 1. Blow air into port A and verify that air flows out from the holes B on the evaporative chamber. kinks or leakage.) 2. 3.INDEX EMISSION SYSTEM PURGE SOLENOID VALVE INSPECTION Simulation Test 1. 1. (Refer to TROUBLESHOOTING. 5.CHAPTER. Install the evaporative chamber. 3. If not as specified. Remove the charcoal canister.INDEX RANG. Remove the purge solenoid valve.TO. 3. Blow air into the charcoal canister from the fuel tank side port and verify that there is no air leakage. replace the purge solenoid valve. CONTINUED F1-26 . (Refer to FUEL SYSTEM. 4.DRFT.

TO.CHAPTER. FROM. CONTINUED F1-27 . MANUAL TO.BACK. Blow through the valve and verify that air flows as specified. Reconnect the negative battery cable. POSITIVE CRANKCASE VENTILATION (PCV) VALVE INSPECTION 1. Repair or replace faulty areas. If not as specified. Remove the PCV valve. Specification Condition Air applied from port A Air applied from port B Airflow Yes No 3.INDEX RANG.INDEX EMISSION SYSTEM Short circuit • Purge solenoid valve connector terminal B and PCM connector terminal 2X through common connector to GND 5. 2. 7. 6. MODEL . Install the purge solenoid valve.DRFT. replace the PCV valve.REPAIR MANUAL PAGES.

REPAIR MANUAL PAGES.CHAPTER.INDEX CONTROL SYSTEM CONTROL SYSTEM CONTROL SYSTEM COMPONENT LOCATION 1 2 3 4 5 6 7 PCM MAF sensor TP sensor CTP switch IAT sensor ECT sensor CMP sensor (In distributor) 8 9 10 11 12 13 O2S (Europe only) Variable resistor (Except Europe) Clutch switch Neutral switch PSP switch Main relay CONTINUED F1-28 .INDEX RANG. MODEL . MANUAL TO.TO.BACK. FROM.DRFT.

When measuring the following PID value. If a monitored value of an output device is out of specification. 2. F1-29 CONTINUED . FROM.INDEX RANG. Connect the SSTs (NGS tester) to the DLC. Remove in the order indicated in the table.) (Refer to Not Using the SSTs (NGS tester) at Ground (GND) Terminal Inspection. 3. Select the "PID/DATA MONITOR AND RECORD" function on the NGS tester display and press TRIGGER. inspect the monitored value of the input device related to the output control.) 4. 3.REPAIR MANUAL PAGES. (Refer to ON-BOARD DIAGNOSTIC SYSTEM.) 6.DRFT.BACK. Therefore.TO. MANUAL TO. MAIN RELAY INSPECTION. follow the instruction in action column. 1. Go to the appropriate part inspection page. Note • Perform the SIMULATION TEST for the output device (A/C RLY.) 1. Disconnect the negative battery cable. IACV. an output device malfunction is not directly indicated as a malfunction of the monitored value for the output device. 4. Measure the PID value. Remove the cowl side panel (driver's side). Install in the reverse order of removal. Select the appropriate PID on the NGS tester display and press START. Note • The PID/DATA MONITOR function monitors the calculated value of the input/output signals in the PCM. If PID value is not within the specification. ENGINE COOLANT TEMPERATURE (ECT) SENSOR INSPECTION. PID/DATA MONITOR AND RECORD PROCEDURE. 1 PCM 2 PCM connector PCM INSPECTION Using SSTs (NGS tester) Note • PIDs for the following parts are not available on this model. (Refer to ON-BOARD DIAGNOSTIC SYSTEM. NGS Tester Hook-up Procedure. ONBOARD DIAGNOSTIC TEST. Turn the ignition switch on. use a voltmeter to measure the PCM terminal voltage.) 3.INDEX CONTROL SYSTEM PCM REMOVAL/INSTALLATION 1. MODEL . Water temperature sender unit (Integrated with ECT sensor) (Refer to CONTROL SYSTEM. CMP sensor (Refer to CONTROL SYSTEM.CHAPTER. perform the following: TP V PID (Refer to Not Using the SSTs (NGS tester) at Constant Voltage Terminal Inspection.) 2. • • • For input/output signals except those of the monitoring items. CAMSHAFT POSITION (CMP) SENSOR INSPECTION.) 2. 5. PRGV) after PID/DATA measurement is completed. FP RLY. Main relay (Refer to CONTROL SYSTEM.

MAIN RELAY INSPECTION Inspect battery. NL SW. ☞ Section G DTC P1195 is indicated. ☞ CONTROL SYSTEM. Follow DTC Troubleshooting ☞ ON-BOARD DIAGNOSTIC SYSTEM. 2. ENGINE COOLANT TEMPERATURE (ECT) SENSOR INSPECTION Inspect engine coolant temperature sensor.0 V Ignition switch on: 0.REPAIR MANUAL PAGES. MAF V. PSP SW. ☞ CONTROL SYSTEM.0 V Brake pedal depressed: ON Brake pedal released: OFF Accelerator depressed: OFF Accelerator released: ON - ON/OFF 1O ON/OFF 1N ECT (Engine coolant temperature) ECT V (ECT signal voltage) °C °F Engine coolant temperature 20 °C {68°F}: 20°C {68°F} Engine coolant temperature 60 °C {140°F}: 60°C {140°F} Engine coolant temperature 20 °C {68 °F}. Inspect fuel pump relay.CHAPTER.DRFT. switch on: ON ☞ Section U A/C switch off at ignition switch on: OFF Inspect main relay.INDEX CONTROL SYSTEM PID MONITOR Table Monitor item (Definition) A/C RLY (A/C relay) A/C SW (A/C switch) Unit/ Condition ON/OFF Condition/Specification Ignition switch on: OFF A/C switch on and fan switch on at idle: ON Action Inspect following PIDs: RPM. w CONTROL SYSTEM. ECT V. ECT V. CLT SW. MANUAL TO. Inspect A/C relay. ☞ INTAKE-AIR SYSTEM. A/C SW. FROM. IDLE AIR CONTROL (IAC) VALVE INSPECTION 1H IACV (Idle air control valve) ms Idle: 2.25 mile} above sea level: 100—103 kPa {1.9—4.5V Ignition switch on: OFF Idle: ON Cranking: ON 2Q V 2Q FHO2S*1 (Oxygen sensor) V Inspect O2S.5—1.4—2.0 V Acceleration (after warm up): 0. ☞ CONTROL SYSTEM. OXYGEN SENSOR O2S) INSPECTION 2N FPRLY (Fuel pump relay) ON/OFF Inspect following PID: RPM.0 V Deceleration (after warm up): 0—0.2—2.0 V After warm up: 0.1—1. A/C SW. TEN.INDEX RANG.01—1. Inspect idle air control valve. RPM. ☞ Section U PCM terminal 1J ON/OFF A/C switch and fan switch on at ignition Inspect A/C switch.25 mile} above sea level: 3. CLOSED THROTTLE POSITION (CTP) SWITCH INSPECTION Inspect engine coolant temperature sensor.4V After warms up: Below 1. ☞ Section P Inspect CTP switch ☞ CONTROL SYSTEM.TO. Follow DTC Troubleshooting ☞ ON-BOARD DIAGNOSTIC SYSTEM. FUEL PUMP RELAY INSPECTION Inspect following PIDs: IATV. DTC INSPECTION Inspect brake switch.05 kgf/cm2} - V Below 400 m {0. TP V.7 ms 2W 1 : Europe only *2: Except Europe CONTINUED F1-30 . TP V. ☞ FUEL SYSTEM.1—1. MODEL .BACK. ENGINE COOLANT TEMPERATURE (ECT) SENSOR INSPECTION 1Q B+ (Battery positive voltage) V Constant: B+ 1B BARO*2 (Barometric pressure) BARO V*2 (Barometric pressure signal voltage) BRKSW (Brake switch) CTP SW (Idle switch) kPa Below 400 m {0. DTC INSPECTION DTC P1195 is indicated.

CLUTCH SWITCH INSPECTION PCM terminal Intake air temperature 20 °C {68 °F}:20°C{68 °F} 2L V Intake air temperature 20 °C {68 °F}: 2. TP V.7 V 2L IGT (Ignition timing) Terminal TEN (DLC) BTC short to ground: A—6 BTC Idle: 1—30 BTC 2F INJ (Fuel injection duration) ms Ignition switch on: 0.INDEX RANG. PSP SW.TO.DRFT.8 V 20 ON/OFF Constant: ON 1L Neutral position and clutch pedal depressed: ON Others: OFF 1V *1: Europe only CONTINUED F1-31 .CONTROL SYSTEM. PSP SW.REPAIR MANUAL PAGES. CONTROL SYSTEM. TP V. ECT V. . A/C SW.5—2.CONTROL SYSTEM. BRK SW. -CONTROL SYSTEM. Inspect CMP sensor. NL SW. TEN. MODEL .0 ms Idle: 3. FHO2S. MANUAL TO. CAMSHAFT POSITION (CMP) SENSOR INSPECTION Inspect mass air flow sensor. Inspect following PIDs: MAF V.0—5. RPM.INDEX CONTROL SYSTEM Monitor item (Definition) IATDC (Intake air temperature (Dynamic chamber)) IATDC V (IAT signal voltage (Dymanic chamber)) Unit/ Condition °C Condition/Specification Action Inspect IAT sensor rar -CONTROL SYSTEM. CAMSHAFT POSITION (CMP) SENSOR INSPECTION Inspect idle speed and ignition timing. INTAKE AIR TEMPERATURE (IAT) SENSOR INSPECTION Inspect IAT sensor -CONTROL SYSTEM. INTAKE AIR TEMPERATURE (IAT) SENSOR INSPECTION Inspect following PIDs: MAF V.9—2.0 V Idle: 1. NEUTRAL SWITCH INSPECTION Inspect clutch switch. B+.CHAPTER. NL SW. A/C SW. -CONTROL SYSTEM.ENGINE TUNE-UP. FROM. MASS AIR FLOW (MAF) SENSOR INSPECTION Inspect neutral switch.0—2. . IAT V.0 ms 2U 2V MAFV (Mass air flow signal voltage) MT/AT*1 (MT/AT distinction signal) NLSW (Load/no load condition signal) ON/OFF V Ignition switch on: 1.BACK. . IAT V. RPM. ECT V. Inspect CMP sensor.

CRANKSHAFT POSITION SENSOR INSPECTION Inspect wiring from DLC terminal TEN to PCM terminal 1L Inspect TP sensor. WARNING AND INDICATOR SYSTEM.INDEX CONTROL SYSTEM Monitor item (Definition) PRCV (Pressure regulator control) PRGV (Purge solenoid valve duty value) % Ignition switch on: 0% Idle: 0% ON/OFF Unit/ Condition Condition/Specification Ignition switch on: OFF Idle: OFF Engine start at hot condition: ON Action Inspect following PIDs: ECTV. ☞ FUEL SYSTEM. ☞ CONTROL SYSTEM. ☞ CONTROL SYSTEM. Inspect PRC solenoid valve. TP V.DRFT. THROTTLE POSITION (TP) SENSOR INSPECTION Inspect variable resistor ☞ VARIABLE RESISTOR INSPECTION Inspect vehicle speedometer sensor PGM terminal 2T 2X PSP SW (PSP switch) ON/OFF Steering wheel fully turned: ON Steering wheel straight ahead position: OFF 1P RPM (Engine speed) TEN (TEN terminal (DLC)) TP V (TP sensor signal voltage) VRV*2 (Variable resistor) RPM Idle: 700—770 RPM 2E ON/OFF Terminal TEN (DLC) short to ground: ON Terminal TEN (DLC) open: OFF Closed throttle position: 0. RPM.0 V Turned fully counterclockwise: Approx 4. FHO2S. Inspect purge solenoid valve. ECT V. POWER STEERING PRESSURE (PSP) SWITCH INSPECTION Inspect CMP sensor.6 V Wide open throttle: 3.CHAPTER. ☞ EMISSION SYSTEM.INDEX RANG. ☞ CONTROL SYSTEM. PURGE SOLENOID VALVE INSPECTION Inspect PSP switch. IAT V.4—4. MANUAL TO. B+. MODEL . MAP V. RPM.TO. PRC SOLENOID VALVE INSPECTION Inspect following PIDs: IATV. FROM.REPAIR MANUAL PAGES. INSTRUMENT CLUSTER INSPECTION Inspect vehicle speed sensor 1M VS (Vehicle speed) KPH Vehicle speed 40 km/h {mph}: 40 km/h {mph} *2: Except Europe CONTINUED F1 -32 .BACK.7 V 1K V 2M V Turned fully clockwise: below 1.TP V.0 V Vehicle speed 20 km/h {mph}: 20 km/h {mph} 2N ☞ Section T.4—0. B+.

Not Using the SSTs (NGS Tester) at Instrument Cluster (Engine speed signal) Terminal Inspection 1. If not as specified. Disconnect the PCM connectors. (3) When measurement voltage is B+.BACK. (1) When measurement voltage is 0 V. Turn the ignition switch on. PCM GND terminal 2A 2B 2C 4. Measure the voltage between the TP sensor and variable resistor (Except Europe) connector (vehicle side) terminal A and body GND using a voltmeter. Not Using the SSTs (NGS Tester) at Power Supply Terminal Inspection 1. 3. repair the related harnesses. 2. If there is continuity. CONTINUED F1-33 . 3.DRFT. 2. repair the related harnesses. repair the related harnesses. 4. When measurement voltage is approx. • Constant voltage terminal of PCM is okay. Using an ohmmeter. 3. Not Using the SSTs (NGS Tester) at Serial Communication Terminal Inspection 1. 2. Turn the ignition switch off.REPAIR MANUAL PAGES. 2. Disconnect the PCM connector and instrument cluster connector (26 pin). Verify there is continuity between PCM connector terminal 2F and instrument cluster connector (20 pin) terminal 3B. If there is continuity. inspect for continuity between the PCM connector (vehicle side) terminal 2D and TP sensor and variable resistor (Except Europe) connector (vehicle side) terminal C which is applied to constant voltage. If there is no continuity. Disconnect the PCM connectors. repair the related harnesses. Turn the ignition switch off. Turn the ignition switch off. Verify there is continuity between PCM connector terminal 1 D and DLC KLN terminal. Turn the ignition switch off. Measure the voltage between the PCM battery power terminal connectors and body GND using an ohmmeter. ③ Verify there is no continuity between the TP sensor and variable resistor (Except Europe) connector (vehicle side) terminal C and battery positive harness using an ohmmeter. Inspect for continuity between the PCM GND terminals and body GND using an ohmmeter. Not Using the SSTs (NGS tester) at Ground (GND) Terminal Inspection 1. ① Turn the ignition switch off. ② Disconnect the battery positive harness. repair the related harnesses and replace the faulty fuses. If there is no continuity. MODEL . ② Disconnect the TP sensor and variable resistor (Except Europe) connector (applied to constant voltage). Power supply terminal 1A Power supply terminal voltage: B+ 4. ① Turn the ignition switch off. 3. repair the related harness. Disconnect the PCM connectors. If there is no continuity. 4. then battery negative harness. MANUAL TO.TO.CHAPTER. ④ If there is continuity. repair the related harnesses. ③ ④ ⑤ ⑥ (2) Verify there is no continuity between the TP sensor and variable resistor (Except Europe) connector (vehicle side) terminal C and body GND using an ohmmeter. FROM.INDEX RANG. 5V.INDEX CONTROL SYSTEM Not Using the SSTs (NGS tester) at Constant Voltage Terminal Inspection 1. 2.

Remove the PCM. inspect related systems. ☞ section U Inspect related harness. 1K Diagnostic test mode DLC Ignition switch (Terminal TEN) on Inspect related harness. Ignition switch on DLC and terminal TEN (Terminal FEN) (in DLC) short to chassis ground — —— — Ignition switch on No DTC stored DTC stored — • Inspect related harness. FROM. 4. PCM Terminal Voltage (Reference) Note • With the PCM connector connected. 1L*1 Transmission distinction Ground Constant Inspect related harness. If any incorrect voltage is detected.0 • Below 1.0 B+ • Below 1. — 1I — — A/C relay — Ignition switch on Ignition switch off A/C switch on A/C switch off A/C switch on A/C switch off Terminal TEN (DLC) open Terminal TEN (DLC) short to ground — B+ B+ • Below 1. body ground the voltmeter negative (-) lead and measure voltage at each PCM terminal by inserting the voltmeter positive (+) lead. Reconnect PCM connector and battery negative terminal. 2. Always carry out a total inspection of the input systems.0 Below 1. Inspect related harness.DRFT. MANUAL TO. — — • 1H Fuel pump control Fuel pump relay Cranking Idle • Inspect fuel pump relay. Measure the voltage at PCM terminal using a voltmeter. 3. and PCM to determine the cause of trouble. MODEL . ☞ FUEL SYSTEM. wiring harnesses and connectors referring to the action column in the terminal voltage list. Terminal 1A 1B 1C Signal Back-up power supply Power supply — Serial communication Connected to Battery Main relay — Constant Test condition Voltage (V) B+ 0 B+ — • • • Action Inspect ROOM fuse. Inspect related harness.TO.FUEL PUMP INSPECTION Inspect related harness. 1.CHAPTER.BACK. output systems.INDEX CONTROL SYSTEM Using voltmeter Caution • The PCM terminal voltages vary with change in measuring conditions and vehicle conditions. a wrong diagnosis will be made.0 0 • 1J A/C control Inspect A/C relay. Otherwise. *1: Europe only CONTINUED F1-34 .INDEX RANG.REPAIR MANUAL PAGES. — Ignition switch off Ignition switch on — 1D Carry out inspection according to DTC.0 0-B+ — — B+ Below 1.0 1E 1F 1G DTC output — — • Inspect related harness. DTC output is a part of serial DLC communication. (Terminal KLN) Judgement by terminal voltage is not possible. Below 1.

5.INDEX CONTROL SYSTEM Terminal 1M Signal Vehicle speed Connected to VSS Test condition Vehicle stopped Vehicle running Accelerator pedal depressed Accelerator pedal released Voltage (V) Action • Inspect VSS.DRFT.TO.8—2. 1P Power steering pressure PSP switch Idle 1Q 1R 1S 1T 1U A/C 1V Load/no load distinction Neutral/clutch Ignition switch switch on 2A 2B 2C Fuel injector ground Power ground System ground Ground Ground Ground MAF sensor.3 Below 1.0 B+ • Inspect CTP switch.5 — — — — 4.TP sensor Constant Constant Constant 2D Analog ground Constant Below 1.35—0. O2S.0 • • B+ • Below 1. MANUAL TO.0 • • • Inspect PSP switch.REPAIR MANUAL PAGES. FROM. ☞ CAMSHAFT POSITION (CMP) SENSOR INSPECTION Inspect related harness.0 1. Inspect related harness. 2E SGT Ignition switch on CMP sensor (integrated into distributor) Idle Ignition switch on Idle — — — — Ignition switch on 5. MODEL . Inspect related harness. ☞ section P Below 1. 5. ☞ section G Inspect related harness.0 • Inspect related harness. ☞ CLUTCH SWITCH INSPECTION Inspect related harness. — — — — 2F 2G 2H 2I 2J 2K IGT control — — — — Ignition control module — — — — • Constant voltage TP sensor (Vref) • Inspect related harness.0 • Inspect related harness.0 • Inspect related harness.0 • Below 1.0 0. ECT sensor. Inspect ignition control module. ☞ POWER STEERING PRESSURE (PSP) SWITCH INSPECTION Inspect related harness.0 • Below 1.INDEX RANG. ☞ NEUTRAL SWITCH INSPECTION Inspect clutch switch. IAT sensor. 1N CTP CTP switch Ignition switch on • Brake pedal depressed 1O Brake Brake switch Brake pedal released Steering wheel straight ahead position Steering wheel fully turned A/C switch — — — — — — — — Ignition switch on A/C switch and fan switch on A/C switch off — — — — Transmission neutral position or clutch pedal depressed Other than transmission neutral or clutch pedal released • Inspect brake switch. B+ Below 1. • B+ Below 1.BACK. Inspect A/C switch. — — — — Inspect neutral switch. ☞ CLOSED THROTLE POSITION (CTP) SWITCH INSPECTION Inspect related harness.0 ☞ section T Approx. ☞ section U Inspect related harness. 0 or Approx.5 • • • Inspect CMP sensor. F1-35 CONTINUED .0 B+ — — — — Below 1.CHAPTER.0 • Below 1. Inspect related harness.5—5.

after engine start Ignition switch on 0 0 B+ B+ B+ B+ B+ 0. ☞ MASS AIR FLOW (MAF) SENSOR INSPECTION Inspect related harness. 2M TP TP sensor Accelerator pedal released Accelerator pedal depressed Engine cold After warm up 0.45 2.4 • • 2W IAC IAC valve Idle (after warm up) • *1: Europe only *2: Except Europe CONTINUED F1-36 .7 0. ☞ FUEL SYSTEM.0—1. Inspect fuel injector.FUEL INJECTOR INSPECTION Inspect related harness.CHAPTER.6 3. Inspect fuel injector. Inspect O2S.TO. ☞ THROTTLE POSITION (TP) SENSOR INSPECTION Inspect related harness.No.5—1.3 Ignition switch on Idle Ignition switch on Idle Ignition switch on • • Fuel injector No. ☞ INTAKE AIR TEMPERATURE (IAT) SENSOR INSPECTION Inspect related harness. Inspect variable resistor. MANUAL TO.INDEX RANG. after ignition switch on For 120 sec.4—4.REPAIR MANUAL PAGES.15 • Ignition switch on Ignition switch on 2N* 1 Action Inspect IAT sensor. PRC SOLENOID VALVE INSPECTION Inspect related harness.0 0. ☞ INTAKE-AIR SYSTEM.4—0.BACK. MODEL .2. ☞ ENGINE COOLANT TEMPERATURE (ECT) SENSOR INSPECTION Inspect related harness.FUEL INJECTOR INSPECTION Inspect related harness. Inspect TP sensor. No.DRFT.55 0. Inspect MAF sensor.0—1.0—0. — • Inspect ECT sensor. ☞ FUEL SYSTEM.73 — 1. IAC VALVE INSPECTION Inspect related harness. ☞ OXYGEN SENSOR (O2S) INSPECTION Inspect related harness.02 • • 2O Mass airflow MAP sensor Idle (after warm up) Engine speed 3000 rpm (after warm up) 2P — — — IAT 20°C {68°F} 2Q ECT ECT sensor Ignition switch on After warm up 0.0 0.0 0. ☞ VARIABLE RESISTOR INSPECTION Inspect related harness.5 • • • • • O2S O2S Idle Acceleration Deceleration 2N* 2 Varies according to the variable Variable resistor Variable resistor resistor adjustment Ignition switch on 0—4 • 1. Inspect IAC valve. — — • Inspect PRC solenoid valve.1.15 2. ☞ FUEL SYSTEM. FROM.2 Approx 1.0 • • • 2R 2S — — — — — — ECT above 90°C {194°F} (Hot condition) Others 2T Pressure PRC solenoid regulator control valve 2U Fuel injector control 2V Fuel injector No.58 — — For 120 sec.INDEX CONTROL SYSTEM Terminal Signal Connected to Test condition Voltage (V) • 2L IAT IAT sensor Ignition switch on IAT 20° C {68°F} 2.

inspect as follows and repair or replace as necessary: 3. If the MAF sensor PID value is out of specification.CHAPTER. If any of the above are found.9—7. ☞ FUEL SYSTEM. FUEL INJECTOR INSPECTION Inspect related harness. MANUAL TO. MODEL . Inspect that the accelerator cable free play is within the specification. 5. ☞ EMISSION SYSTEM. Open circuit • MAF signal circuit (MAF sensor connector terminal B and PCM connector terminal 20) • Power circuit (MAF sensor connector terminal C and main relay terminal D through common connector) • GND circuit (MAF sensor connector terminal A and PCM connector terminal 2D through common connector) THROTTLE POSITION (TP) SENSOR INSPECTION Note • Perform the following test only when directed.) 3.TO. 4. Disconnect the TP sensor connector. • Damage • Cracks • Terminal bends • Terminal rust 2.INDEX CONTROL SYSTEM Terminal Signal Connected to Test condition Ignition switch on 2X Purge control Purge solenoid valve Idle Driving in gear 2Y — Engine speed output — — — • B+ 4. 2. Visually inspect for the following on the MAF sensor. ACCELERATOR CABLE INSPECTION / ADJUSTMENT. (Refer to INTAKE-AIR SYSTEM. FROM. PURGE SOLENOID VALVE INSPECTION Inspect related harness. If not as specified. If as specified but PID valve is out of specification.REPAIR MANUAL PAGES. — Inspect instrument cluster. replace the TP sensor.BACK. Specification 4—6KΩ Short circuit • MAF signal circuit (MAF sensor connector terminal B and PCM connector terminal 20 to GND) • Power circuit (MAF sensor connector terminal C and main relay terminal D through common connector to GND) 4. 2Z Tachometer Ignition switch on (integrated into instrument cluster) Idle MASS AIR FLOW (MAF) SENSOR INSPECTION Note • Perform the following test only when directed.0 • Voltage (V) B+ B+ • • Action Inspect purge solenoid valve. inspect for the following: Open circuit • Reference voltage circuit (TP sensor connector terminal A and PCM connector terminal 2K) • TP signal circuit (TP sensor connector terminal B and PCM connector terminal 2M) • GND circuit (TP sensor connector terminal C and PCM connector terminal 2D) Short circuit • Reference voltage circuit (TP sensor connector terminal A and PCM connector terminal 2K) • TP signal circuit (TP sensor connector terminal B and PCM connector terminal 2M) CONTINUED F1-37 . 5. Verify that the throttle valve is at closed throttle position. Disconnect the MAF sensor connector. measure the resistance between TP sensor terminals A and C using an ohmmeter. Resistance Inspection 1. replace the MAF sensor. Repair or replace faulty areas. MAF Sensor Inspection 1. If as specified. Reconnect the MAF sensor connector.DRFT.INDEX RANG.

INDEX RANG.) THROTTLE POSITION (TP) SENSOR REMOVAL/INSTALLATION 1. MANUAL TO. Verify that the throttle valve moves smoothly. 6.2—5.5 V 5. Specification (CTP) TP sensor terminal C voltage (V) PCM terminal 2M voltage TP V (NGS tester) (V) 0.6 0.9 4.9 4. replace the TP sensor. Verify that the throttle valve is at closed throttle position. 1.REPAIR MANUAL PAGES.6—4.m {16—24 kgf.cm.5—4. 4. 8.5—5. Turn ignition switch on. Do not adjust the TP sensor excessively. Reconnect the TP sensor connector. Specification (WOT) TP sensor terminal C voltage (V) 4. Remove the TP sensor screws. 2.0—5. Reconnect the TP sensor connector. 14—20 in.lbf} 9.6—2.1—5.9—5. • Since the TP sensor is adjusted by the manufacturer. FROM.2 Specification 4. Repair or replace faulty areas.6 4.8 3. Tightening torque 1.0 4.5—4.0 5. 5.5 PCM terminal 2M voltage TP V (NGS tester) (V) 3.8—4.4—0. 2. THROTTLE POSITION (TP) SENSOR REMOVAL / INSTALLATION.8—4.6 0.1 5.1 4. (Refer to CONTROL SYSTEM. Disconnect the TP sensor connector.3—5.1—5.INDEX CONTROL SYSTEM 6.8 4.6 3.1—5.9—5.1 5. Install the TP sensor to the throttle body.4—4. If not as specified.4—0.4 3. Disconnect the TP sensor connector. MODEL .CHAPTER.0—5. 3. Reconnect the TP sensor connector.3 N. Use the NGS tester ("TP V" of PID/DATA MONITOR AND RECORD function) or voltmeter to adjust the TP sensor so that the voltage of PCM terminal 2M is within the specification below when the throttle valve is at the closed throttle position.4—5.9 4.m {16—24 kgf.4—0. F1-38 CONTINUED . 14—20 in.7—4.7—4. 3. 7. Do not adjust the TP sensor with the TAS.lbf } 7.3 N.4 5.5 8. adjusting the TP sensor excessively can adversely affect the engine. Measure and record the voltage of the disconnected harness side connector terminal C using a voltmeter. Tighten the TP sensor screw.6—2.7 4. Verify that the throttle valve is fully closed. Use the NGS tester ("TP V" of PID/DATA MONITOR AND RECORD function) or voltmeter to verify the TP sensor so that the voltage of PCM terminal 2M is within the specification below when the throttle valve is wide open. Remove the TP sensor from the throttle body. Tightening torque 1.cm.3 5. THROTTLE POSITION (TP) SENSOR ADJUSTMENT Caution • Adjusting the TP sensor with the throttle adjusting screw (TAS) can adversely affect the engine.TO. Loosen the TP sensor screw.5 3.DRFT.7—4. 7. 10. tighten the TP sensor screws. 6.BACK. 4.

274 —0. 2. 1.802 3. Measure the resistance of the IAT sensor using an ohmmeter Specification Measuring condition Closed throttle position Others Continuity Yes No Specification Water temperature (°C {°F}) 20 {68} 80 {176} Resistance (kΩ ) 2. Reconnect the IAT sensor connector. Disconnect the CTP switch connector.REPAIR MANUAL PAGES. but PID value is out of specification. Adjust the TP sensor. Remove the IAT sensor.DRFT. Open circuit • IAT signal circuit (IAT sensor connector terminal A and PCM connector terminal 2L) • GND circuit (IAT sensor connector terminal B and PCM connector terminal 2D) Short circuit • IAT signal circuit (IAT sensor connector terminal A and PCM connector terminal 2Lto GND) 5.09— 2. • Removing the closed throttle position switch can negatively affect the engine.) CLOSED THROTTLE POSITION (CTP) SWITCH INSPECTION Caution • The CTP switch is set at the factory. Do not try to adjust it.81 0. inspect as follows and repair or replace as necessary. replace the throttle body.TO.INDEX CONTROL SYSTEM 9. Open circuit • CTP signal circuit (CTP switch connector terminal and PCM connector terminal 1N) • GND circuit (CTP switch body to GND) 4. FROM. replace the IAT sensor.CHAPTER. If not as specified.BACK. Short circuit • CTP signal circuit (CTP switch connector terminal and PCM connector terminal 1 N to GND) 4. 1. Inspect for continuity between the CTP switch terminal and a GND using an ohmmeter. 2. inspect as follows and repair or replace as necessary. If not as specified. Note • Perform the following test only when directed. MANUAL TO. CONTINUED F1-39 . If IAT sensor is okay.INDEX RANG. 3. INTAKE AIR TEMPERATURE (IAT) SENSOR INSPECTION Resistance inspection Note • Perform the following test only when directed. MODEL . Reconnect CTP switch connector. Heat the IAT sensor using the lamp. THROTTLE POSITION (TP) SENSOR ADJUSTMENT. If the CTP switch is okay. but PI D value is out of specification. (Refer to CONTROL SYSTEM.

ENGINE COOLANT. Remove the ECT sensor.REPAIR MANUAL PAGES.0 kgf. Measure the resistance between the ECT sensor terminals A and B using an ohmmeter. 1. Remove the IAT sensor. Disconnect the ECT sensor connector. Remove the ECT sensor.29—0. 3.m {80—120 kgf. 70—104 in. Install in the reverse order of removal.INDEX RANG. MANUAL TO. (Refer to Section E.DRFT. 5. ENGINE COOLANT.lbf} 6. If not as specified.cm. but PID value is out of specification. Disconnect the IAT sensor connector. Connect the IAT sensor connector.7 N.) (Refer to Section E. replace the ECT sensor. 3.9—11. (Refer to Section E. Drain the engine coolant.) F1-40 CONTINUED . 6. 19—21 ft. 3.) 2.4 5. COOLING SYSTEM SERVICE WARNINGS. MODEL .) (Refer to Section E. Refill the engine coolant.m. ENGINE COOLANT TEMPERATURE (ECT) SENSOR REMOVAL/INSTALLATION Warning • When the engine is hot. ENGINE COOLANT REPLACEMENT. 4.m {2.8 80 {176} 0. COOLING SYSTEM SERVICE WARNINGS. and heat the water gradually. inspect for the following: Open circuit • ECT signal circuit (ECT sensor connector terminal A and PCM connector terminal 2Q through common connector) • GND circuit (ECT sensor connector terminal B and PCM connector terminal 2D through common connector) Short circuit • ECT signal circuit (ECT sensor connector terminal A and PCM connector terminal 2Q through common connector to GND) • GND circuit (ECT sensor connector terminal B and PCM connector terminal 2D through common connector to GND) 6. FROM. Tightening torque 7. ENGINE COOLANT REPLACEMENT. Disconnect the negative battery cable. Drain the engine coolant.INDEX CONTROL SYSTEM INTAKE AIR TEMPERATURE (IAT) SENSOR REMOVAL/INSTALLATION 1. (Refer to Section E. ENGINE COOLANT TEMPERATURE (ECT) SENSOR INSPECTION Note • Perform the following test only when directed. If the ECT sensor is okay.CHAPTER. ENGINE COOLANT. 4.lbf} 5.5—3.TO. ECT Sensor Resistance Inspection 1.2—2.BACK.) 2. ENGINE COOLANT REPLACEMENT. Replace the gasket. Connect the negative battery cable. it can badly burn. 2. Turn off the engine and wait until it is cool before removing or installing the ECT sensor. Place the ECT sensor in water with a thermometer. Repair or replace faulty areas. Tightening torque 25—29 N.) (Refer to Section E. Specification Water temperature (°C {°F}) Resistance (kΩ ) 20 {68} 2. Install the IAT sensor. 4. COOLING SYSTEM SERVICE WARNINGS.

Warm up the engine and run it at idle. Connect the distributor connector. 8. 8. Disconnect the high-tension lead. inspect for following: F1-41 CONTINUED . MANUAL TO.0 V) Short circuit • SGT signal circuit (Distributor harness side connector terminal C and PCM harness side connector terminal 2E to GND) • Power circuit (Distributor harness side connector terminal B and main relay harness side connector terminal D to GND) 9. Verify the following signal (voltage) from the PCM 2E terminal using a voltmeter when the distributor is rotated by hand. ENGINE COOLANT REPLACEMENT. (Refer to Section E. (Refer to ENGINE TUNE-UP. 5. Remove the distributor.5—0. ENGINE COOLANT. but PID value is out of specification. MODEL . (Approx.BACK.REPAIR MANUAL PAGES. Turn the ignition switch on. which can cause electrical shock. Connect the voltmeter test leads to the following O2S terminals: • (+) lead-O2S terminal A • (-) lead-O2S terminal B 7.5 6. Verify that the voltmeter needle moves when racing the engine several times. If not as specified.0 Deceleration 0—0. Disconnect the O2S connector.DRFT. 4. inspect as follows and repair or replace as necessary. 6.CHAPTER. replace the O2S.7 V. 2. Specification Engine condition Voltage (V) Acceleration 0.) CAMSHAFT POSITION (CMP) SENSOR INSPECTION Note • Perform the following test only when directed.5—1. Disconnect the distributor connector.TO. 2. Voltage Inspection 1.INDEX CONTROL SYSTEM 7. Warning • Turning the ignition switch on with the fuel injector connector still connected will actuate the fuel injector. 3.) (Refer to Section E. FROM. If the O2S is okay. 5. 5.) OXYGEN SENSOR (O2S) INSPECTION O2S Voltage Inspection Note • Perform the following test only when directed. replace the distributor and adjust the ignition timing. Run the engine at 3000 rpm until the voltmeter increases 0. COOLING SYSTEM SERVICE WARNINGS. 3. Disconnect the connector and prevent it from grounding to the vehicle body. If not as specified. Specification Signal Terminal SGT 2E Voltage 4 pulses/rev. Refill the engine coolant.INDEX RANG. Install the ECT sensor. Disconnect the fuel injector connectors. Open circuit • SGT signal circuit (Distributor harness side connector terminal C and PCM harness side connector terminal 2E) • Power circuit (Distributor harness side connector terminal B and main relay harness side connector terminal D) • GND circuit (Distributor harness side connector terminal A and engine GND) 4. IGNITION TIMING ADJUSTMENT. If the harnesses are okay. 1. • Turning the ignition switch on with the distributor connector still connected will generate sparks.

MANUAL TO. 3. 9. 8. Inspect the continuity between the clutch switch terminals A and B using an ohmmeter. Remove the clutch switch. 8. 5. 3. 2. Verify that the clutch switch is installed properly. Connect an ohmmeter between the variable resistor terminal B and C. MODEL . Disconnect the connector from the variable resistor. OXYGEN SENSOR (O2S) REMOVAL/INSTALLATION 1.TO. Tightening torque 29-49 N. Disconnect the battery negative terminal. 2. If the variable resistor is okay. Remove the O2S.m. inspect for the following: Open circuit • Reference voltage circuit (Variable resistor connector terminal A and PCM connector terminal 2K) • Variable resistor signal circuit (Variable resistor connector terminal B and PCM connector terminal 2N) • GND circuit (Variable resistor connector terminal C and PCM connector terminal 2D) Short circuit • Reference voltage circuit (Variable resistor connector terminal A and PCM connector terminal 2K) • Variable resistor signal circuit (Variable resistor connector terminal B and PCM connector terminal 2N) 7. Disconnect the O2S connector.lbf} VARIABLE RESISTOR INSPECTION 1. 22—36 ft.BACK. If not as specified. repair or replace wiring harness. Reconnect the O2S connector. Install in the reverse order of removal. If there is an open or short circuit. 4.INDEX RANG. 3. Reconnect the variable resistor connector. 2. Disconnect the negative battery cable.INDEX CONTROL SYSTEM Open circuit • O2S signal circuit (O2S connector terminal A and PCM connector terminal 2N) • GND circuit (O2S connector terminal B and PCM connector terminal 2D) Variable resistor condition Turned fully clockwise Turned fully counterclockwise Resistance (kΩ ) 4-6 Below 0. If there is no open or short circuit. 4.CHAPTER.1 Short circuit • O2S signal circuit (O2S connector terminal A and PCM connector terminal 2N to GND) 7. Repair or replace faulty areas. Adjust idle mixture. Using the SST .m {3—5 kgf. CONTINUED F1-42 . FROM. 6. CLUTCH SWITCH REMOVAL/INSTALLATION. 1.REPAIR MANUAL PAGES. CLUTCH SWITCH INSPECTION Continuity Inspection Note • Perform the following test only when directed. replace the variable resistor. but PCM terminal 2N or 2K voltage is out of specification. verify that the resistance increases in relation to the turning amount of the variable resistor. (Refer to CONTROL SYSTEM.DRFT. replace variable resistor.) 4.

4. 1. NEUTRAL SWITCH INSPECTION Continuity inspection Note • Perform the following test only when directed. CLUTCH PEDAL INSPECTION/ADJUSTMENT. Reconnect the neutral switch connector. Connect the clutch switch connector. Install the clutch switch. F1-43 CONTINUED . 6. If the neutral switch is okay. (Refer to CONTROL SYSTEM.INDEX CONTROL SYSTEM Specification Specification Transmission In neutral Others Continuity Yes No 5. Adjust the clutch pedal height referring to the above and the height specification. 2. 2. If not as specified. Connect the negative battery cable.BACK.INDEX RANG. 3. but PID value is out of specification. Disconnect the clutch switch connector. replace the clutch switch. Repair or replace faulty areas. If not as specified.) 6. 2. NEUTRAL SWITCH REMOVAL/INSTALLATION 1. Repair or replace faulty areas.TO. Disconnect the neutral switch connector. Install the new washer and neutral switch. Disconnect the battery negative cable. inspect for the following: Open circuit • Power circuit (Clutch switch connector terminal B and PCM connector terminal 1V through common connector) • GND circuit (Clutch switch connector terminal A and GND) Short circuit • Power circuit (Clutch switch connector terminal B and PCM connector terminal 1V to GND) Neutral switch • The neutral switch operation and related harnesses continuity (Refer to NEUTRAL SWITCH INSPECTION. 7. CLUTCH PEDAL.) 8. MODEL . Loosen the nuts and remove the clutch switch. 4. MANUAL TO. 3. CLUTCH SWITCH REMOVAL/INSTALLATION 1. 4.CHAPTER. inspect for the following: Open circuit • Load/no load distinction circuit (neutral switch connector terminal A and PCM connector terminal 1V through common connector) • GND circuit (neutral switch connector terminal B and GND) Short circuit • Load/no load distinction circuit (neutral switch connector terminal A and PCM connector terminal 1V through common connector to GND) Clutch switch • The clutch switch operation and related harness continuity. Disconnect the neutral switch connector. 7. Disconnect the negative battery cable. (Refer to CONTROL SYSTEM. 6. Measure the continuity between the neutral switch terminals A and B using an ohmmeter.) 5. CLUTCH SWITCH REMOVAL/INSTALLTION. CLUTCH SWITCH INSPECTION. 5. but PID value is out of specification. Connect the negative battery cable. FROM. 3.REPAIR MANUAL PAGES. (Refer to Section H. If the clutch switch is okay.DRFT. replace the neutral switch. Disconnect the battery negative cable. Remove the neutral switch. Install the clutch switch.

MODEL . If not as specified.5 kgf. replace the PSP switch. POWER STEERING PRESSURE (PSP) SWITCH INSPECTION Continuity inspection Note • Perform the following test only when directed. inspect for the following: Open circuit • Main relay power supply circuit (Main relay connector terminal A and ignition switch (IG1) connector through common connector) • PCM power supply circuit (Main relay connector terminal C and battery positive terminal through common connector) CONTINUED F1-44 . MANUAL TO. 3.TO. inspect for the following: Open circuit • PSP signal circuit (PSP switch connector terminal and PCM connector terminal 1P through common connector) GND circuit (PSP switch body and GND) • 4.m {2. Disconnect the PSP switch connector. MAIN RELAY INSPECTION Continuity Inspection Note • Perform the following test only when directed. Inspect for continuity between the PSP switch terminal and GND using an ohmmeter. Connect the battery negative cable. Repair or replace faulty areas. If not as specified. engine speed sensing power steering system. 2.DRFT. replace the main relay. 19—25 ft. Remove the main relay connector. If the PSP switch is okay.lbf} 5. Inspect for continuity between terminals of the relay using an ohmmeter. 3.INDEX RANG.BACK.REPAIR MANUAL PAGES. Specification Condition Steering wheel in straight ahead Steering wheel fully turned Continuity Yes No Specification 4. Connect the neutral switch connector.INDEX CONTROL SYSTEM Tightening torque 25—34 N. 2.CHAPTER. If the main relay is okay.m. 1. 1. Short circuit • PSP signal circuit (PSP switch connector terminal and PCM connector terminal 1P through common connector to GND) Power steering fluid (Refer to Section N. 6.5—3.) • Fluid level • Fluid leakage • Fluid pressure 5. 6. Reconnect the PSP switch connector. but PID value is out of specification. Start the engine. FROM. Disconnect the negative battery cable.

Disconnect the negative battery cable.7 N. Repair or replace faulty areas. ON-BOARD DIAGNOSTIC SYSTEM GND circuit (Main relay connector terminal B and GND) Short circuit • Main relay power supply circuit (Main relay connector terminal A and ignition switch (IG1) connector through common connector to GND) • PCM power supply circuit (Main relay connector terminal C and battery positive terminal through common connector to GND) 5. but is not used for the inspection because the corresponding part (PRC solenoid valve) is not equipped. ON-BOARD DIAGNOSTIC TEST NGS Tester Hook-up Procedure Note • Make sure the ignition switch is at LOCK position.DRFT. or else the test result will be FAULTY. Reconnect the main relay. These tests will verify the PCM status. MANUAL TO. and related circuit wiring harnesses. Install the reverse order of removal.9—10.5—95. There are two options: ALL TEST and SINGLE TEST. Remove the main relay. FROM. ALL TEST takes you through all diagnostic support tests. The "Idling Test" and "Ignition ON Test" are available in this test. CONTINUED F1-45 . 2. SIMULATION TEST • Output devices can be turned on and off by sending simulation command signals from the NGS tester to the PCM. This test MUST follow the instructions on the NGS tester. Disconnect the main relay connector. Reconnect the negative battery cable. perform the Simulation Test to identify which output devices are malfunctioning.REPAIR MANUAL PAGES. PARAMETER IDENTIFICATION (PID) ACCESS • The PID mode allows access to certain data values. 3. calculated values and system status information. If not. MAIN RELAY REMOVAL/INSTALLATION 1.4 in-Ibf} • ON-BOARD DIAGNOSTIC SYSTEM READ/CLEAR DIAGNOSTIC TEST RESULTS • This retrieves all stored DTCs in the PCM and clears the DTC. output devices. Note • "PRCV" of the simulation item can be selected for vehicles without the PRC system. 7. 6. SINGLE TEST enables you to perform specific tests that relate to the particular diagnosis that you are conducting. Insert the vehicle interface module and latest program card into the hand-held NGS control unit. 69. MODEL . a "TEST CONDITIONS NOT CORRECT' message will appear.cm. but is not used for the inspection because the corresponding part (PRC solenoid valve) is not equipped.TO. Tightening torque 7. Note • PID monitor item "PRCV" can be selected and "ON" or "OFF' is displayed for vehicles without the PRC system. Since PID values for output devices are PCM internal data values. 4. DIAGNOSTIC SUPPORT PROCEDURE • These tests are the ability of the powertrain control system to detect a change in certain input devices by following the instructions on the NGS tester. analog and digital inputs and outputs. 1.INDEX RANG.CHAPTER.BACK.m {80—110 kgf.INDEX CONTROL SYSTEM.

turn the ignition switch on during the procedure. MODEL .CHAPTER. Press the TRIGGER key to enter this selection.TO. • 4. Plug the adapter harness connector into the vehicle interface module and the DLC located at the engine compartment. 4. Move the cursor to VEHICLE & ENGINE SELECTION. Listen to the double beep.REPAIR MANUAL PAGES. 3. Move the cursor to SELECT NEW VEHICLE YEAR & MODEL Press the TRIGGER key to enter this selection. EUROPE 2. FROM. MANUAL TO. Hook the NGS tester up to the vehicle. Move the cursor to B-SERIES (UN).DRFT. If the engine will not start. Press the TRIGGER key to enter this function.BACK. DTC READING PROCEDURE Using the SSTs (NGS Tester) Note Start engine and keep it running.INDEX RANG. CONTINUED F1-46 . Begin the powertrain control system functional test. Plug the NGS tester power connector into the cigarette lighter. Perform the necessary vehicle preparation and visual inspection. use a battery hook-up adapter. 2. The NGS tester is now initialized. 1.INDEX ON-BOARD DIAGNOSTIC SYSTEM 3. Alternatively.

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

If any DTCs is indicated.DRFT. Note • Press the TRIGGER key once again to deselect a PID. 6. 4. Not Using the SST s (NGS tester). After completion of repairs. erase all DTCs from the memory. and the positive lead to the DLC terminal +B. 3. erase all DTCs from the memory. Press the TRIGGER key again when ready to save information. 10. (Refer to AFTER REPAIR PROCEDURE. When ready to capture and store the selected PIDs. inspect the appropriate area and repair as necessary. MODEL . If DTC is not detected. Press START to begin. Using the Voltmeter 1. PLAYBACK OF STORED PIDS PROCEDURE Note • Look for abnormal behavior or values that are clearly incorrect. Press the TRIGGER key to enter this selection. the needle does not move. Perform Steps 1 through 7 from the DTC READING PROCEDURE. 7. Not Using the SST s (NGS Tester). F1-48 CONTINUED . 2. press the TRIGGER key.INDEX RANG. The voltmeter indicates B+ for approximately 3 seconds. Perform the NGS Tester Hook-up Procedure. Carefully connect the specified terminals only.INDEX ON-BOARD DIAGNOSTIC SYSTEM 7. Read the DTCs indicated by the movement of the voltmeter's needle. then indicates 0V.) 8. After completion of repairs. Remove the voltmeter and jumper wire PID/DATA MONITOR AND RECORD PROCEDURE 1. • Press the CLEAR to deselect all PIDs.REPAIR MANUAL PAGES. 8. 3. FROM. Move the cursor to STORE RECORDING AREA 1. MANUAL TO.) 9. Using a jumper wire to short terminal TEN of the DLC to body GND. Move the cursor to PID/DATA MONITOR AND RECORD. Press the TRIGGER key. Turn the ignition switch on or run the engine. Connect the negative battery lead of voltmeter (20V range) to the DLC terminal FEN. Follow the instructions displayed on the NGS tester to save the recording data. Caution • Connecting the wrong DLC terminals may possibly cause a malfunction. 7. 4. Inspect the signals for abrupt or unexpected changes. 6. Turn the ignition switch on.CHAPTER. Note • The DTC will be output as shown. A star symbol will appear next to the item when it is selected. Remove the SST s. 8. (Refer to AFTER REPAIR PROCEDURE. 2.TO. 5. Turn the ignition switch off.BACK. 9. Move the cursor to PID values to view. Press the TRIGGER key. 5.

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

Press the TRIGGER key to enter this selection.BACK. 10. above 550 CONTINUED F1-50 . The screen will display a list of simulation items. 3. 6. Start the engine and run it at idle. Ignition ON Test 1.TO. Move the cursor to IGNITION ON TEST . Select the appropriate simulation item for testing. 2.CHAPTER. then press the TRIGGER key. press the CANCEL key. Press the TRIGGER key to enter this selection. Move the cursor to IDLING TEST . 2. 9. Note • If the screen displays "TEST CONDITION NOT CORRECT ". press the TRIGGER key.DRFT. 4. Perform Steps 1 through 7 from the DTCs READING PROCEDURE. Press the TRIGGER key to enter this selection. MANUAL TO. 5. Press the TRIGGER key. Press START . 3. The simulation is performed for 3 seconds. MODEL . Move the cursor to SIMULATION TEST . Perform the Steps 1 through 7 from the DTC READING PROCEDURE. 8. inspect the following signal conditions and determine whether or not they are normal: • NLSW: ON • RPM.INDEX RANG. Note • Only one simulation item can be selected at a time.REPAIR MANUAL PAGES. Press the TRIGGER key to enter this selection. 7.INDEX ON-BOARD DIAGNOSTIC SYSTEM SIMULATION TEST PROCEDURE Idling Test 1. To perform the simulation again. and a "SIMULATION ACTIVATED PLEASE WAIT" message is displayed during those 3 seconds. Turn the ignition switch on. FROM. To exit the idling test. Move the cursor to SIMULATION TEST . Perform the NGS tester hook-up procedure.

MODEL . FROM. 5. Note • If the engine will not start. 8. Ensure that the customer's concern has been resolved. The simulation is performed for 3 seconds. To exit the ignition on test. Press the CANCEL key. To perform the simulation again. Reconnect the negative battery cable. The screen will display a list of simulation items. Press CLEAR. then press the TRIGGER key.INDEX ON-BOARD DIAGNOSTIC SYSTEM AFTER REPAIR PROCEDURE Using the SSTs (NGS Tester) 1. 4. 2. Perform the "DTC READING PROCEDURE" again. Press the TRIGGER key. Press the TRIGGER key. 5.BACK. press the CANCEL key.TO. After repairs. 4. and a "SIMULATION ACTIVATED PLEASE WAIT" message is displayed during those 3 seconds. 7. and depress the brake pedal. Warm up the engine to normal operating temperature. press the TRIGGER key. continue to operate the starter for 5-6 seconds.INDEX RANG. Verify that the DTC is not detected. MANUAL TO. CONTINUED F1-51 . After repairs have been made. 3. 4.CHAPTER. 6. perform the DTCs READING PROCEDURE. Press START . disconnect the negative battery cable for at least 20 seconds. Not Using the SSTs (NGS Tester) 1.DRFT.REPAIR MANUAL PAGES. 3. Select the appropriate simulation item for testing. 2.

BACK.TO.REPAIR MANUAL PAGES.DRFT. MANUAL TO.INDEX RANG.INDEX ON-BOARD DIAGNOSTIC SYSTEM DTC INSPECTION DTC Table DTC No. FROM. P0100 P0115 P0120 P0134 P0340 P0443 P0505 P1110 P1170 P1195 P1250 P1608 Output pattern Display on the NGS tester MAF/VAF-CIRCUIT MALFUNCTION ECT-CIRCUIT MALFUNCTION Condition MAF sensor circuit malfunction ECT sensor circuit malfunction TP-CIRCUIT MALFUNCTION TP sensor circuit malfunction O2S 11-CIRCUITNO ACTIVITY DETECTED CAMSHAFT POS SENSORCKT MALFUNCTION EVAP SYSTEM-PURGE CTRL VALVE CKT MALF IDLE CONTROL SYSTEMMALFUNCTION O2S circuit no activity detected SGT signal is not detected Purge solenoid valve circuit malfunction IAC valve circuit malfunction IATS (D/C)-OPEN OR SHORT IAT sensor circuit malfunction HO2S 11-INVERSION EGRBS-OPEN OR SHORT PRC-OPEN OR SHORT PCM (CPU)-MALFUNCTION O2S is stuck Barometric pressure sensor (in PCM) malfunction PRC solenoid valve circuit malfunction PCM internal circuit malfunction CONTINUED F1-52 . MODEL .CHAPTER.

INDEX ON-BOARD DIAGNOSTIC SYSTEM DTC Troubleshooting DTC P0100 DETECTION CONDITION Mass air flow (MAP) sensor circuit malfunction Input voltage from MAF sensor is below 0. Does MAF V PID change when air is blown into mass airflow sensor? Note • If NGS tester is not used. 5 Disconnect PCM connector. then go to Step 12. then go to Step 12. Repair open circuit. Go to next step. engine coolant temperature sensor. Turn ignition switch on. then go to Step 12. Yes Repair short to ground circuit. then go to Step 12.INDEX RANG.BACK. Have DTCs P0115. Go to next step Repair or replace faulty parts. P0120. FROM.7 V or above 5. Inspect for open or short circuit in wiring harness (between main relay terminal D and MAF sensor terminal C).REPAIR MANUAL PAGES. MANUAL TO. CONTINUED F1-53 . Connect NGS tester to DLC. then go to Step 12. Is there any foreign material at MAF sensor screen? Connect MAF sensor connector.CHAPTER. No No Go to next step Go to next step. Is there continuity between MAF sensor harness side No connector terminal A and PCM harness side connector terminal 2D? Is there continuity between MAF sensor harness side connector terminal B and PCM harness side connector terminal 20 Is there continuity from PCM harness side connector terminals 20 to 1B? Is there continuity from PCM harness side connector terminals 20 to body ground. Yes ACTION Inspect for open circuit in following wiring harnesses. then go to Step 12. Go to next step. Go to next step Repair open circuit.DRFT. Is there battery positive voltage at MAF sensor harness side connector terminal C? No Yes No Yes No Yes Repair or replace connector. • • • • • • • • • • MAF sensor malfunction Blockage at MAP sensor Poor connection of connectors at MAF sensor and/or PCM Leakage in intake-air system Short to power supply circuit in wiring from MAF sensor terminal B to PCM terminal 20 Short to ground in wiring from MAF sensor terminal B to PCM terminal 20 Open circuit in wiring from MAF sensor terminal B to PCM terminal 20 Open circuit in wiring from MAF sensor terminal C to main relay terminal D Open circuit in wiring from MAF sensor terminal A to PCM terminal 2D Open circuit in wiring from PCM terminal 2C to engine ground. then go to Step 12. P0340. • Main relay terminal D-purge solenoid valve. MODEL . measure PCM 20 terminal voltage with circuit tester.4 V when ignition switch is turned on. IAC valve CMP sensor • PCM terminal 2D-throttle position sensor. P0134. oxygen sensor • Between PCM terminal 2C and engine ground Go to next step Go to next step.TO. then go to Step 12. No Yes Go to next step. MAF sensor connector is Yes disconnected. Turn ignition switch on. then go to Step 12. P0443. No Replace MAF sensor. and/or P1250 been stored? No 2 3 4 Does MAP sensor connector or PCM connector have poor connection? Is intake-air system okay? Disconnect MAF sensor connector. P0505. intake-air temperature sensor. POSSIBLE CAUSE STEP INSPECTION 1 Verify stored DTC. Access MAF V PID. then go to Step 12. P1170. P1110. Yes No 6 7 8 9 10 Yes Repair short to power circuit. PRC solenoid valve. Remove MAF sensor. Go to next step. Yes Clean MAF sensor screen.

☞ CONTROL SYSTEM. POSSIBLE CAUSE STEP 1 Verify stored DTC. IAT sensor. Is there continuity between ECT sensor harness side connector terminal B and PCM harness side connector terminal 2D Is there continuity from PCM harness side connector terminals 2Q to 1B? Is there continuity from PCM harness side connector terminals 2Q to body ground? Is ECT sensor okay? ☞ CONTROL SYSTEM. Go to next step. Go to applicable DTC inspection. then go to Step 9. Go to next step Go to next step Replace ECT sensor. Is there any DTC present after performing "AFTER REPAIR PROCEDURE"? Yes No DTC P0115 DETECTION CONDITION Engine coolant temperature (ECT) sensor circuit malfunction Input voltage from ECT sensor is below 0. • • • • • • • ECT sensor malfunction Poor connection of connectors at ECT sensor terminal and/or PCM Short to power supply circuit in wiring from ECT sensor terminal A to PCM terminal 2Q Short to ground in wiring from ECT sensor terminal A to PCM terminal 2Q Open circuit in wiring from ECT sensor terminal A to PCM terminal 2Q Open circuit in wiring from ECT sensor terminal B to PCM terminal 2D Open circuit in wiring from PCM terminal 2C to engine ground INSPECTION ACTION Yes Inspect for open circuit in following wiring harnesses. ACTION 12 Clear DTC from memory. O2S. Is same DTC present after performing "AFTER REPAIR PROCEDURE"? Yes No Go to Step 1. then go to Step 9. MANUAL TO.BACK.07 V or above 4.INDEX RANG. Troubleshooting completed. Go to next step Go to next step Inspect for open or short circuit in wiring harness (between PCM terminal 2Q and ECT sensor terminal A).TO. P0120. Turn ignition switch on.CHAPTER. Repair connectors and/or harnesses. then go to next step. Repair open circuit. ENGINE COOLANT TEMPERATURE (ECT) SENSOR REMOVAL/INSTALLATION. ECT sensor connector is disconnected. and/or P1170 been stored? No 2 3 Does ECT sensor connector or PCM connector have poor connection? Disconnect ECT sensor connector. then go to Step 9. FROM. Intermittent poor connection in wiring harnesses or connectors. then go to Step 9 Go to next step. MODEL . then go to Step 9 Repair short to power circuit. Repair short to ground circuit. • PCM terminal 2D-MAF sensor. ENGINE COOLANT TEMPERATURE (ECT) SENSOR INSPECTION Yes No Yes No 4 Yes No Yes No Yes No Yes No 5 6 7 F1-54 CONTINUED . Have DTCs P0100. then go to Step 9. Is there 5V at engine coolant temperature sensor harness side connector terminal A Disconnect PCM connector. and/or TP sensor • PCM terminal 2C-engine ground Go to next step Repair or replace connector. then go to Step 9.DRFT.INDEX ON-BOARD DIAGNOSTIC SYSTEM STEP 11 INSPECTION Clear DTC from memory. P0134. P1110.58 V when ignition switch is turned on.REPAIR MANUAL PAGES.

TO.REPAIR MANUAL PAGES.09 V or above 4. Repair open circuit. Yes TP sensor is disconnected. Repair or replace wiring harness. Is there any DTC present after performing "AFTER REPAIR PROCEDURE"? Yes No DTC P0120 DETECTION CONDITION Throttle position (TP) sensor circuit malfunction Input voltage from TP sensor is below 0. P0134. Is there continuity between TP sensor harness side connector terminal No C and PCM harness side connector terminal 2D. then go to Step 11 Go to next step.INDEX ON-BOARD DIAGNOSTIC SYSTEM STEP 8 INSPECTION Clear DTC from memory. Go to applicable DTC inspection. Go to next step. MODEL . Is there 5V at TP sensor harness side connector terminal A? Yes No Yes No 4 Disconnect PCM connector. MANUAL TO. Intermittent poor connection in wiring harness or connector. P1110 and/or P1170 been stored. then go to Step 11. O2S. FROM. • • • • • • • • • • • TP sensor malfunction Poor connection of connectors at TP sensor and/or PCM Short to power supply circuit in wiring from TP sensor terminal A to PCM terminal 2K Short to power supply circuit in wiring from TP sensor terminal C to PCM terminal 2D Short to power supply circuit in wiring from TP sensor terminal B to PCM terminal 2M Short to ground in wiring from TP sensor terminal B to PCM terminal 2M Short to ground in wiring from TP sensor terminal A to PCM terminal 2K Open circuit in wiring from TP sensor terminal A to PCM terminal 2K Open circuit in wiring from TP sensor terminal C to PCM terminal 2D Open circuit in wiring from TP sensor terminal B to PCM terminal 2M Open circuit in wiring from TP sensor terminal 2C to engine ground INSPECTION ACTION Yes Inspect for open or short circuit in following wiring harnesses. Go to next step. ACTION 9 Clear DTC from memory.CHAPTER. P0115. and/or ECT sensor • Between PCM terminal 2C and engine ground Go to next step Repair or replace connector. Have DTC P0100.DRFT. Turn ignition switch on. IAT sensor. POSSIBLE CAUSE STEP 1 Verify stored DTC. Inspect for open or short circuit in wiring harness (between PCM terminal 2K and TP sensor terminal A). then go to Step 11. Is same DTC present after performing "AFTER REPAIR PROCEDURE"? Yes No Go to Step 1.78 V when ignition switch is turned on. then go to next step. Troubleshooting completed. Yes No 5 CONTINUED F1-55 . then go to Step 11 Go to next step. No 2 3 Does TP sensor connector or PCM connector have poor connection? Disconnect TP sensor connector. Is there continuity between TP sensor harness side connector terminal B and PCM harness side connector terminal 2M. • PCM terminal 2D -MAP sensor.INDEX RANG. then go to Step 11. Repair connector and/or harness.BACK.

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

45 V after the engine is started. and engine is run at idle? Note • If NGS tester is not used. FROM. ECT and VS PIDs. Read following warnings before performing fuel system service: • Fuel vapor is hazardous. Fuel can also irritate skin and eyes. 3 Yes Implement TROUBLESHOOTING.REPAIR MANUAL PAGES. ① ECT sensor (terminal 2Q) ② SGT (terminal 2E) ③ TP sensor (terminal 2M) Yes No Yes ACTION Inspect and repair DTC P0100. P0115 and/or P1110 been stored? Clear DTC. Have DTC P0100 P0120. ENGINE SYMPTOM TROUBLESHOOTING. • • • • • • • • • • • • • • • O2S malfunction Open or short circuit in wiring harness Open or short circuit in wiring harness Poor connection of connector Fuel injector malfunction Pressure regulator malfunction Fuel pump malfunction Fuel delivery hose and/or fuel filter clogging or leakage Leakage in intake-air system Leakage in exhaust system Ignition coil and/or igniter malfunction Insufficient compression MAF sensor malfunction ECT sensor malfunction TP sensor malfunction Vacuum hose damage or looseness POSSIBLE CAUSE Warning Following troubleshooting flow chart contains fuel system diagnosis and repair procedures. P0120 or P1110 then go to Step 22. Is DTC P0134 stored? Note • If NGS tester is not used. Intermittent concerns". MODEL . 2 No Go to 'TROUBLESHOOTING. P0115. Fuel can ignite and cause serious injuries or death and damage. ① SGT (terminal 2E) ② ECT sensor (terminal 2Q) ③ Vehicle speed (terminal 1M) Implement PID/DATA MONITOR AND RECORD (ECT. Drive in normal mode for approx.TO. BEFORE REPAIR PROCEDURE ☞ FUEL SYSTEM. It can easily ignite. Always keep sparks and flames away from fuel • Fuel line spills and leakage are dangerous.INDEX RANG. AFTER REPAIR PROCEDURE STEP 1 INSPECTION Verify stored DTC. Input Signal System Investigation Procedure" and repair or replace. or stays below 0. ENGINE DIAGNOSTIC INSPECTION. always complete "BEFORE REPAIR PROCEDURE" and "AFTER REPAIR PROCEDURE" described in this manual ☞ FUEL SYSTEM. then go to Step 22. Verify RPM. TP V) from DIAGNOSTIC DATA LINK by using NGS tester. Go to next step. CONTINUED F1-57 .DRFT. Is there any signal that is far out of specification when ignition switch is on.INDEX ON-BOARD DIAGNOSTIC SYSTEM DTC P0134 DETECTION CONDITION Oxygen sensor (O2S) circuit no activity detected O2S signal does not exceed 0. MANUAL TO. RPM.CHAPTER. No Go to next step. causing serious injury and damage.BACK.45 V for 180 seconds after the engine has reached normal operating temperature. 2 minutes under same condition. measure following PCM terminal voltages with circuit tester. To prevent this. Go to next step Trouble is in process. measure follow PCM terminal voltages with circuit tester.

MODEL .INDEX RANG. ☞ FUEL SYSTEM. Install O2S properly. Go to next step Go to next step. Go to next step. then go to Step 22.INDEX ON-BOARD DIAGNOSTIC SYSTEM STEP 4 INSPECTION Continue monitoring items in previous step. Go to next step.BACK. Inspect for open. then go to Step 22. OXYGEN SENSOR (O2S) INSPECTION. then go to Step 22. FROM.DRFT. ☞ FUEL SYSTEM. No Yes 9 No Yes 10 No Go to next step. Can air suction be confirmed? Inspect for suction in vacuum hose which has negative pressure on intake manifold. FUEL INJECTOR INSPECTION. Fuel Pressure Inspection. then go to Step 22. Go to next step. and inspect fluctuation after spraying rust penetrating agent. Is fuel line pressure okay? Inspect fuel pump maximum pressure. ☞ EXHAUST SYSTEM. Go to next step. Are there foreign materials on fuel side of fuel filter? Yes No Inspect and repair or replace faulty oxygen sensor harness. Go to Step 16. ☞ CONTROL SYSTEM. Is voltage on oxygen sensor as follows while racing engine (in neutral)? • More than 0. ENGINE SYSTEM INSPECTION. Is it okay? Inspect for clogging in fuel filter (high-pressure). Fuel Injection Volume Test. Fuel Pump Maximum Pressure Inspection. 12 13 14 Yes No F1-58 CONTINUED . ☞ TROUBLESHOOTING. MANUAL TO. poor connection. FUEL PUMP UNIT REMOVAL/INSTALLATION. ☞ FUEL SYSTEM. ENGINE DIAGNOSTIC INSPECTION. FUEL INJECTOR REMOVAL/INSTALLATION. Go to next step. connector or terminal. Go to Step 17. FUEL PUMP UNIT INSPECTION. 11 Yes No Yes No Yes No Repair or replace source of air suction. then go to Step 22.45V when accelerator pedal is suddenly pressed: rich condition • Less than 0. Go to next step. Is there any input signal. then go to Step 22. which causes drastic changes when it is set to be in trouble condition? Yes ACTION Implement 'TROUBLESHOOTING. measure PCM 2N terminal voltage with circuit tester. connectors and terminals (for fuel injector at each cylinder): • Front main relay to fuel injector Are there any problems? Inspect injection amount of each fuel injector. and other problems on following harnesses. then go to Step 22.TO. ☞ FUEL SYSTEM. No 5 Inspect exhaust system upstream from oxygen sensor. OXYGEN SENSOR (O2S) REMOVAL/INSTALLATION.45V during fuel cut: lean condition Note • If NGS tester is not used. 8 Yes Repair or replace faulty harness. ☞ CONTROL SYSTEM. connector or terminal. Go to next step. Repair or replace source of air suction. Are there any fuel injectors in abnormal condition for amount or condition of injection? Inspect for air suction: • From air cleaner to throttle body • From throttle body to dynamic chamber • From dynamic chamber to intake manifold Visually inspect for cracks and damage. EXHAUST SYSTEM REMOVAL/INSTALLATION. in the same manner as previous step. Replace faulty fuel injectors. then go to Step 22. Go to next step Replace fuel pump.REPAIR MANUAL PAGES. Is it okay? Yes No 7 Implement PID/DATA MONITOR AND RECORD (O2S) from DIAGNOSTIC DATA LINK using NGS tester. Can air suction be confirmed? Inspect fuel line pressure under trouble condition. then select air suction area. Input Signal System Investigation Procedure" and repair or replace. Is there any gas leakage? Yes No 6 Inspect installation of O2S. then go to Step 22.CHAPTER. Repair or replace faulty exhaust parts.

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

Have DTC PP0100.DRFT. POSSIBLE CAUSE STEP 1 No 2 3 Does CMP sensor or PCM connector have poor connection? Disconnect CMP sensor connector. Turn ignition switch on.INDEX RANG. then go to Step 11. Is same DTC present after performing "AFTER REPAIR PROCEDURE"? Yes No Yes No Replace distributor and adjust ignition timing. Inspect for open or short circuit in wiring harness (between main relay terminal D and CMP sensor terminal B).BACK.CHAPTER. Go to next step. Repair open circuit. Connect NGS tester to DLC. FROM. Turn ignition switch on. Troubleshooting completed. Go to next step. Repair short to ground circuit. then go to Step 11. measure PCM 2E terminal voltage with circuit tester. Is there any DTC present after performing "AFTER REPAIR PROCEDURE"? Yes No CONTINUED F1-60 . Go to next step.TO. MODEL . Is there battery positive voltage at CMP sensor harness side connector terminal B? Disconnect CMP sensor connector. then go to next step. then go to Step 11. Go to next step Go to next step. P0505. and/or P1250 been stored? Yes ACTION Inspect for open circuit in following wiring harnesses.INDEX ON-BOARD DIAGNOSTIC SYSTEM DTC P0340 DETECTION CONDITION SGT signal is not detected No SGT signal input from CMP sensor when engine is started and 2. then go to Step 11. Access RPM PID. MANUAL TO. PRC solenoid valve. Is there 5 V at CMP sensor harness side connector terminal C? Disconnect PCM connector and CMP sensor connector. Clear DTC from memory. 11 Clear DTC from memory.1 seconds have passed • • • • • • • • CMP sensor malfunction CMP sensor air gap incorrect Short to power supply circuit in wiring from CMP sensor terminal C to PCM terminal 2E Short to ground in wiring from CMP sensor terminal C to PCM terminal 2E Short to ground in wiring from CMP sensor terminal B to main relay terminal D Open circuit in wiring from CMP sensor terminal C to PCM terminal 2E Open circuit in wiring from CMP sensor terminal B to main relay terminal D Open circuit in wiring from CMP sensor terminal A to body ground INSPECTION Verify stored DTC.REPAIR MANUAL PAGES. 10 Yes No Go to Step 1 Intermittent poor connection in wiring harnesses or connectors. then go to Step 11. Repair connectors and/or harnesses. Is there continuity between CMP sensor harness side connector terminal C and PCM harness side connector terminal 2E? Yes No Yes No 4 Yes No 5 Yes No 6 7 8 9 Is there continuity from PCM harness side connector Yes terminal 2E to 1B? No Is there continuity from PCM harness side connector Yes terminal 2E to body ground? No Is there continuity from CMP sensor harness side terminal A to body ground? Connect CMP sensor connector. IAC solenoid valve. P0443. Repair or replace connector. Turn ignition switch on. then go to Step 11. Repair open circuit. then go to Step 11. Inspect for open or short circuit in wiring harness (between PCM terminal 2E and CMP terminal C). Go to next step. MAF sensor Go to next step. Go to next step. then go to Step 11. Repair short to power circuit. Go to applicable DTC inspection. Go to next step. Does RPM PID change when engine is running? Note • If NGS tester is not used. • Main relay terminal D-purg solenoid valve. then go to Step 11.

P0505. Is there continuity between purge solenoid valve harness side connector terminal B and PCM harness side connector terminal 2X? Is there continuity from PCM harness side connector terminal 2X to 1B? Is there continuity from PCM harness side connector terminal 2X to body ground? Is purge solenoid valve okay? ☞ EMISSION SYSTEM. Inspect for open or short circuit in wiring harness (between main relay terminal D and purge solenoid valve terminal A).REPAIR MANUAL PAGES. • Main relay terminal D-PRC solenoid valve. Repair short to ground circuit. P0340. IAC solenoid valve. then go to next step. then go to Step 9. PURGE SOLENOID VALVE INSPECTION Clear DTC from memory.INDEX RANG. Is same DTC present after performing "AFTER REPAIR PROCEDURE"? Yes No Yes No 4 Yes No Yes No 5 6 7 Yes No Yes No Yes No 8 9 Clear DTC from memory. Go to next step. MAF sensor.CHAPTER. then go to Step 9. then go to step 9. Have DTC P0100. Turn ignition switch on. • • • • • • • Purge solenoid valve malfunction Poor connection of connectors at purge solenoid valve and/or PCM Short to power supply circuit in wiring from purge solenoid valve B to PCM terminal 2X Short to ground in wiring from purge solenoid valve terminal B to PCM terminal 2X Open circuit in wiring from PCM terminal 2B and/or 2C to engine ground Open circuit in wiring from purge solenoid valve terminal B to PCM terminal 2X Open circuit in wiring from purge solenoid valve terminal A to main relay terminal D INSPECTION ACTION Yes Inspect for open circuit following wiring harnesses. MANUAL TO. Intermittent poor connection in wiring harness or connector. Go to next step.TO. Repair short to power supply circuit. CMP sensor • Between PCM terminal 2C and engine ground Go to next step Repair or replace connector.DRFT. Go to Step 1. then go to Step 9. and/or P1250 been stored? No 2 3 Does purge solenoid valve connector or PCM connector have poor connection? Disconnect purge solenoid valve connector. Go to applicable DTC inspection. FROM. then go to Step 9. then go to Step 9. then go to Step 9. Go to next step Replace purge solenoid valve. Is there battery positive voltage at purge solenoid valve harness side connector terminal A? Disconnect PCM connector Purge solenoid valve is disconnected. Is there any DTC present after performing "AFTER REPAIR PROCEDURE"? Yes No F1-61 CONTINUED . Repair open circuit. Go to next step.BACK. MODEL . POSSIBLE CAUSE STEP 1 Verify stored DTC. Go to next step. Troubleshooting completed.INDEX ON-BOARD DIAGNOSTIC SYSTEM DTC P0443 DETECTION CONDITION Purge solenoid valve circuit malfunction Open or short circuit is observed in purge solenoid valve system when ignition switch is turned on. Go to next step. Repair connector and/or harness.

INDEX ON-BOARD DIAGNOSTIC SYSTEM DTC P0505 DETECTION CONDITION Idle air control (IAC) valve circuit malfunction Open or short circuit is observed in idle air control. No Is there battery positive voltage at IAC valve harness side connector terminal A? Disconnect PCM connector IAC valve is disconnected. Inspect for open or short circuit in wiring harness (between main relay terminal D and IAC valve terminal A). • Main relay terminal D-PRC solenoid valve.REPAIR MANUAL PAGES.INDEX RANG. Go to applicable DTC inspection Troubleshooting completed No 2 3 Does IAC valve connector or PCM connector have poor connection? Yes No Disconnect IAC valve connector. P0443. then go to Step 9. Is same DTC present after performing "AFTER REPAIR PROCEDURE"? Yes No Yes No 6 7 8 9 Clear DTC from memory. MANUAL TO. MODEL . Go to next step Go to next step. Go to next step. Repair short to power supply circuit.5 Ω [23 °C {73. then go to Step 9.BACK. P0340. Go to next step Go to next step. system IAC valve malfunction Poor connection of connectors at IAC valve and/or PCM Short to ground in wiring from IAC valve terminal B to PCM terminal 2W Short to power supply circuit in wiring from IAC valve terminal B to PCM terminal 2W Short to ground in wiring from IAC valve terminal A to main relay terminal D Open circuit in wiring from PCM terminal 2B and/or 2C to engine ground Open circuit in wiring from IAC valve terminal B to PCM terminal 2W Open circuit in wiring from IAC valve terminal A to main relay terminal D POSSIBLE CAUSE STEP 1 INSPECTION Verify stored DTC.7—10.DRFT. then go to Step 9. then go to next step.CHAPTER. and/or P1250 been stored. then go to step 9.TO. then go to Step 9. Repair short to ground circuit. CMP sensor. Go to next step. then go to Step 9. then go to Step 9. Have DTC P0100.4 °F}] Clear DTC from memory. FROM. Repair open circuit. MAF sensor. Repair connector and/or harness. purge solenoid valve • Between PCM terminal 2C and engine ground Go to next step Repair or replace connector. Replace IAC valve. Yes Turn ignition switch on. Go to Step 1 Intermittent poor connection in wiring harness or connector. Is there continuity between IAC valve harness side connector terminal B and PCM harness side connector terminal 2W? Yes No 4 5 Is there continuity from PCM harness side connector Yes terminal 2W to 1B? No Is there continuity from PCM harness side connector Yes terminal 2W to body ground? No Is resistance between IAC valve component side connector A and B as specified? Specification 8. Yes ACTION Inspect for open circuit following wiring harnesses. Is there any DTC present after performing "AFTER REPAIR PROCEDURE"? Yes No F1-62 CONTINUED .

Repair short to power circuit.DRFT.INDEX ON-BOARD DIAGNOSTIC SYSTEM DTC P1110 DETECTION CONDITION Intake air temperature (IAT) sensor circuit malfunction Input from IAT sensor is below 0.9 V when ignition switch is turned on • • • • • • • IAT sensor malfunction Poor connection of connectors at IAT sensor terminal and/or PCM Short to power supply circuit in wiring from IAT sensor terminal A to PCM terminal 2L Short to GND in wiring from IAT sensor terminal A to PCM terminal 2L Open circuit in wiring from IAT sensor terminal A to PCM terminal 2L Open circuit in wiring from IAT sensor terminal B to PCM terminal 2D Open circuit in wiring from PCM terminal 2C to engine GND INSPECTION ACTION Yes Inspect for open circuit in following wiring harnesses. Is there continuity between IAT sensor harness side connector terminal B and PCM harness side connector terminal 2D? Is there continuity from PCM harness side connector terminals 2L to 1B? Is there continuity from PCM harness side connector terminal 2D to body GND? Is IAT sensor okay? ☞ CONTROL SYSTEM. Go to next step. then go to Step 9. MAP sensor. Go to next step. then go to Step 9. Go to next step. INTAKE AIR TEMPERATURE (IAT) SENSOR INSPECTION Yes No Yes No 4 Yes No Yes No Yes No Yes No 5 6 7 8 Clear DTC from memory. MANUAL TO. then go to Step 9. then go to next step. Have DTC P0100. Is there any DTC present after performing "AFTER REPAIR PROCEDURE"? Yes No 9 Yes No CONTINUED F1-63 . CMP sensor and/or TP sensor • PCM terminal 2C-engine GND Go to next step. ☞ CONTROL SYSTEM. Is there 5V at IAT sensor harness side connector terminal A? Disconnect PCM connector. POSSIBLE CAUSE STEP 1 Verify stored DTC. P0115. and/or P1170 been stored? No 2 3 Does IAT sensor connector or PCM connector have poor connection? Disconnect IAT sensor connector.1 V or above 4. INTAKE AIR TEMPERATURE (IAT) SENSOR REMOVAL/INSTALLATION Go to Step 1. then go to Step 9.TO. P0335. • PCM terminal 2D-ECT sensor. Intermittent poor connection in wiring harness or connector. Repair connector and/or harness. Go to next step. P0120. Troubleshooting completed. then go to Step 9.CHAPTER. Inspect for open or short circuit in wiring harness (between PCM terminal 2L and IAT sensor terminal A). FROM.INDEX RANG. Repair short to ground circuit. then go to Step 7. Go to next step. Go to applicable DTC inspection. O2S.REPAIR MANUAL PAGES. Is same DTC present after performing "AFTER REPAIR PROCEDURE"? Clear DTC from memory. Replace IAT sensor. P0134. Repair or replace connector. IAT sensor connector is disconnected.BACK. MODEL . then go to Step 9. Repair open circuit. Go to next step. Turn ignition switch on.

It can easily ignite. Have DTCs P0100. causing serious injury and damage. or P0120. ☞ FUEL SYSTEM. BEFORE REPAIR PROCEDURE ☞ FUEL SYSTEM. and/or P0120 been stored? Yes ACTION Inspect and repair DTC P0100. Fuel can also Irritate skin and eyes.DRFT.BACK.TO.INDEX ON-BOARD DIAGNOSTIC SYSTEM DTCP1170 DETECTION CONDITION Oxygen sensor (O2S) is stuck When O2S signal stays above 0.INDEX RANG. Go to Step 26. • Fuel line spills and leakage are dangerous.CHAPTER. FROM. To prevent this. Fuel can ignite and cause serious Injuries or death and damage. No CONTINUED F1-64 . Go to next step. • • • • • • • • • • • • • • • O2S deterioration Fuel injector malfunction Pressure regulator malfunction Fuel pump malfunction Fuel delivery hose clogging or leakage Fuel return hose and/or fuel filter clogging Leakage in intake-air system or exhaust system PCV valve malfunction Purge solenoid valve malfunction or purge solenoid hoses are hooked up incorrectly Ignition coil malfunction Insufficient compression MAF sensor malfunction ECT sensor malfunction TP sensor malfunction Open or short circuit in wiring harness Poor connection of connector Vacuum hose damage or looseness POSSIBLE CAUSE Warning Following troubleshooting flowchart contains fuel system diagnosis and repair procedures. MANUAL TO. P0115. AFTER REPAIR PROCEDURE STEP 1 INSPECTION Verify stored DTC.45V for 20 seconds after engine has reached normal operating temperature. Read following warnings before performing fuel system service: • Fuel vapor is hazardous. P0110. Always keep sparks and flames away from fuel. always complete "BEFORE REPAIR PROCEDURE" and "AFTER REPAIR PROCEDURE" described in this manual. MODEL .REPAIR MANUAL PAGES. P0110 P0115.

then go to Step 26. Install heated oxygen sensor properly. ☞ EXHAUST SYSTEM. 8 Yes Repair or replace faulty harness.INDEX ON-BOARD DIAGNOSTIC SYSTEM STEP 2 INSPECTION Clear DTC. No Go to TROUBLESHOOTING. Is there any input signal which causes drastic changes when it is set to be in trouble condition? Yes ACTION Trouble is in process. and terminals (for fuel injector at each cylinder): • From main relay to fuel injector • From fuel injector to PCM Is there any trouble? Yes No Inspect and repair or replace faulty O2S. Go to next step.INDEX RANG. Repair or replace faulty exhaust parts. Go to next step. 1 minute under same condition. Intermittent Concerns. Is DTC P1170 stored? Note • If NGS tester is not used. Go to next step. Verify RPM. No F1-65 CONTINUED . Input Signal System Investigation Procedure and repair or replace. Go to next step. harnesses. TP V) from DIAGNOSTIC DATA LINK using NGS tester. then go to Step 26.45V when accelerator pedal is suddenly pressed: rich condition • Less than 0. then go to Step 26. upstream from O2S. ① SGT (terminal 2E) ② ECT sensor (terminal 2Q) ③ Vehicle speed (terminal 1 M) Implement PID/DATA.45V during fuel cut: lean condition Note • If NGS tester is not used. and engine is run at idle? Note • If NGS tester is not used. Go to next step. ENGINE SYMPTOM TROUBLESHOOTING.REPAIR MANUAL PAGES. ENGINE DIAGNOSTIC INSPECTION.TO. MODEL . measure following PCM terminal voltage with voltmeter. No 5 Inspect exhaust system. Is there any signal that is far out of specification when ignition switch is on. 3 Yes Implement TROUBLESHOOTING. measure following PCM terminal voltage with voltmeter. OXYGEN SENSOR (O2S) INSPECTION. Drive vehicle approx. Yes Implement TROUBLESHOOTING. connector or terminal. measure PCM 2N voltages with voltmeter. then go to Step 26. connectors.DRFT. connector or terminals. ENGINE DIAGNOSTIC INSPECTION. poor connection and other problems on the following harnesses. No Go to next step. Is voltage on O2S as follows while racing engine (in neutral)? • More than 0. FROM. MANUAL TO.CHAPTER. Input Signal System Investigation Procedure and repair or replace then go to Step 26. EXHAUST SYSTEM REMOVAL/INSTALLATION. ① ECT sensor (terminal 2Q) ② SGT (terminal 2E) ③ TP sensor (terminal 2K) 4 Continue monitoring items on previous PIDs. OXYGEN SENSOR (O2S) REMOVAL/INSTALLATION.MONITOR AND RECORD (ECT.BACK. then go to Step 26. Is there any gas leakage? Yes No 6 Is O2S installed properly? Yes No 7 Implement FID/DATA MONITOR AND RECORD (O2S) from DIAGNOSTIC DATA LINK using NGS tester. Go to next step. ☞ CONTROL SYSTEM. ECT and VS PIDS. RPM. ☞ CONTROL SYSTEM. Inspect for open.

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

then run engine at idle. then go to Step 26. Is it okay? Clear DTC. Scalding coolant and steam may shoot out and cause serious injury. then go to next step. which make engine coolant white at filling opening? Note • Large bubbles are normal since they are remaining air coming out from engine coolant passage.5 V when ignition switch is turned on. COMPRESSION INSPECTION. 25 Inspect engine compression. PCM REMOVAL/INSTALLATION CONTINUED F1-67 . No 22 Verify blinking condition on each cylinder by setting timing light on high-tension lead under trouble condition. MANUAL TO. MODEL . IGNITION COIL INSPECTION.CHAPTER. Verify DTC after running vehicle. Air gets in from poor sealing on head gasket or other areas between combustion chamber and engine coolant passage. then go to Step 26. wrap a thick cloth around and turn it slowly. then go to Step 26. Remove radiator cap. Are there any small bubbles. INSPECTION _ _ ACTION Replace PCM ☞ CONTROL SYSTEM.BACK.INDEX RANG.INDEX ON-BOARD DIAGNOSTIC SYSTEM STEP 21 INSPECTION Inspect for leakage in fuel line from fuel filter (highpressure) to fuel tank (return side).TO. Troubleshooting completed. ☞ FUEL SYSTEM. 26 DTC P1195 DETECTION CONDITION POSSIBLE CAUSE STEP _ Barometric pressure (BARO) sensor (in PCM) Input voltage from barometric pressure sensor is below 1. • Barometric pressure sensor (in PCM) malfunction. Repair or replace faulty parts. Repair or replace source of fuel leakage. Is it okay? Warning • Removing the radiator cap when the radiator is hot is dangerous.REPAIR MANUAL PAGES.DRFT.5 V or above 4. Is there any DTC stored? Yes No Yes No Yes No Yes No Yes 23 24 No Go to next step. FROM. Go to next step. Does it blink regularly and stably? Inspect resistance of ignition coil. ☞Section B1. Replace ignition coil. Implement engine overhaul. Implement procedure to bleed air from engine coolant. Is it okay? Yes ACTION Replace pressure regulator. • When removing the radiator cap. then go to Step 26 Go to Step 24 Go to next step. Go to applicable DTC inspection. Go to next step. ☞Section G. PRESSURE REGULATOR REMOVAL/INSTALLATION.

Repair short to power supply circuit. MAF sensor. Intermittent poor connection in wiring harnesses or connectors. MANUAL TO. Is there continuity between PRC solenoid valve harness side connector terminal B and PCM harness side connector terminal 2T? Is there continuity between PCM harness side connector terminals 2T and 1B? Is there continuity from PCM harness side connector terminal 2T to body GND? Is PRC solenoid valve okay? ☞ FUEL SYSTEM. P0335. then go to Step 9. Repair short to GND circuit. Go to next step.TO. Turn ignition switch on. Is there any DTC present after performing "AFTER REPAIR PROCEDURE"? Yes No CONTINUED F1-68 . Is same DTC present after performing "AFTER REPAIR PROCEDURE"? Yes No Yes No 4 Yes No Yes No 5 6 7 Yes No Yes No Yes No 8 9 Clear DTC from memory. then go to Step 9. • Main relay terminal D-IAC valve. Go to next step. (between main relay terminal D and PRC solenoid valve terminal A). Go to next step. then go to Step 9. Go to next step. PRESSURE REGULATOR CONTROL (PRC) SOLENOID VALVE INSPECTION Clear DTC from memory. then go to next step. purge solenoid valve • Between PCM terminal 2C and engine ground. Go to next step. Go to applicable DTC inspection.DRFT.INDEX ON-BOARD DIAGNOSTIC SYSTEM DTC P1250 DETECTION CONDITION PRESSURE REGULATOR CONTROL (PRC) solenoid valve circuit malfunction Open or short circuit is observed in PRC solenoid valve when Ignition switch is turned on • • • • • • • • PRC solenoid valve malfunction Poor connection of connectors at PRC solenoid valve and/or PCM Short to power supply circuit in wiring from PRC solenoid valve B to PCM terminal 2T Short to GND in wiring from PRC solenoid valve terminal B to PCM terminal 2T Short to GND in wiring from PRC solenoid valve terminal A to main relay terminal D Open circuit in wiring from PCM terminal 2T and/or 2C to engine GND Open circuit in wiring from PRC solenoid valve terminal B to PCM terminal 2T Open circuit in wiring from PRC solenoid valve terminal A to man relay terminal D INSPECTION Verify stored DTC. CMP sensor. Repair or replace connector. PRC solenoid valve. Go to Step 1. then go to Step 9.INDEX RANG. MODEL . P0443 and/or P0505 been stored? Yes ACTION Inspect for open circuit in following wiring harnesses. Have DTCs P0100. Is there battery positive voltage at harness side connector terminal A? Disconnect PCM connector. then go to Step 9. FROM. Go to next step.CHAPTER.REPAIR MANUAL PAGES. POSSIBLE CAUSE STEP 1 No 2 3 Does PRC solenoid valve connector or PCM connector have poor connection? Disconnect PRC solenoid valve connector. then go to Step 9. Repair connectors and/or harnesses. PRC solenoid valve is disconnected.BACK. Troubleshooting completed. Inspect for open or short circuit in wiring harness. Replace PRC solenoid valve. Go to next step. Repair open circuit. then go to Step 9.

INDEX RANG. PRC solenoid valve.INDEX ON-BOARD DIAGNOSTIC SYSTEM DTCP1608 DETECTION CONDITION POSSIBLE CAUSE PCM internal circuit malfunction PCM does not read DTC from output devices.CHAPTER. PCM REMOVAL/INSTALLATION Replace PCM ☞ CONTROL SYSTEM.BACK. Replace PCM. MODEL . IAC solenoid valve and/or fuel injectors) to PCM Yes ACTION Repair short to power supply circuit. PCM REMOVAL/INSTALLATION STEP INSPECTION 1 Disconnect output devices and PCM connector. Short to power supply circuit in wiring from output devices (purge solenoid valve. MANUAL TO.TO. ☞ CONTROL SYSTEM. • • PCM does not read DTC from output devices. FROM.DRFT.REPAIR MANUAL PAGES. Is there continuity between the following connectors? • PCM harness side connector terminal 2X-1B • PCM harness side connector terminal 2E-1B • PCM harness side connector terminal 2W-1B • PCM harness side connector terminal 2U-1B • PCM harness side connector terminal 2V-1B No CONTINUED F1-69 .

Engine takes excessive period for reaching normal operating temperature. Engine runs at higher than normal temperature/overheats. Engine speed fluctuates during acceleration or cruising.TO. Incorrect constant voltage. Symptom occurs randomly and is difficult to diagnose. Momentary minor irregularity in engine output. Engine stops unexpectedly while cruising.INDEX RANG. Engine takes more time than normal to return to idle speed.REPAIR MANUAL PAGES. Performance is poor under load (e. or white smoke from exhaust system Gasoline fuel smell or visible leakage Engine noise from under hood Vibration from under hood or driveline A/C compressor magnetic clutch does not engage when A/C is turned on. TROUBLESHOOTING ITEM TABLE • Confirm trouble symptom using the following diagnostic index. then go to appropriate troubleshooting chart.INDEX TROUBLESHOOTING TROUBLESHOOTING FOREWORD • Before proceeding with the following troubleshooting. Blue. hot spot in combustion chamber). Engine stops unexpectedly at idle and/or after start.BACK. A/C compressor magnetic clutch does not disengage. Starter cranks engine at normal speed but engine requires excessive cranking time before starting. Engine speed continues at fast idle after warm-up. Oil consumption is excessive. (2) Perform the diagnostic trouble code inspection. MANUAL TO. Engine speed fluctuates between specified idle speed and lower speed and engine shakes excessively.DRFT. Emission compliance test is failed. cruising. Vehicle bucks/jerks during acceleration. 1 2 3 4 5 6 7 8 9 TROUBLESHOOTING ITEM Melting of main or other fuses Will not crank Hard to start/long crank/erratic start/erratic crank Engine stalls After start/at idle Cranks normally but will not start Slow return to idle Engine runs rough/rolling idle Fast idle/runs on Low idle/stalls during deceleration Engine stalls/quits Engine runs rough Misses Buck/jerk Hesitation/stumble Surges Lack/loss of power Knocking/pinging Acceleration/cruise Acceleration/cruise Acceleration/cruise Acceleration/cruise/ deceleration Acceleration Acceleration/cruise Acceleration/cruise Acceleration/cruise Starter does not work. (3) If the diagnostic trouble code is displayed. Engine stops unexpectedly at beginning of acceleration or during acceleration. Fuel economy is unsatisfactory.g. Momentary pause at beginning of acceleration or during acceleration. or deceleration. A/C compressor magnetic clutch does not disengage under WOT. perform "ENGINE TUNE-UP". MODEL . FROM. (4) When the engine can be started. black. proceed with inspection steps for the code.g. (1) Refer to section Gl to understand the basic troubleshooting procedure. power down when climbing hills). Engine misses during acceleration or cruising. Engine runs after ignition switch is turned off. DESCRIPTION — 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 Poor fuel economy Emissions compliance High oil consumption/leakage Cooling system concerns Cooling system concerns Exhaust smoke Fuel odor (in engine compartment) Engine noise Vibration concerns (engine) A/C does not work sufficiently A/C is always on/A/C compressor runs continuously A/C is not cut off under WOT conditions Exhaust sulphur smell Intermittent concerns Constant voltage Overheating Runs cold CONTINUED F1-70 . Rotten egg smell (sulphur) from exhaust. Engine stops unexpectedly at beginning of deceleration or recovery from deceleration. Starter cranks engine at normal speed but engine will not run.CHAPTER. No. Sound is produced when air/fuel mixture is ignited by something other than spark plug (e.

MANUAL TO. etc.INDEX TROUBLESHOOTING QUICK DIAGNOSTIC CHART Possible factor Starter motor malfunction (Mechanical or electrical) Engine or transmission mounts improperly installed x Cooling system malfunction (Radiator.DRFT. MODEL . 23 A/C is always on/A/C compressor runs continuously x x 24 A/C is not cut off under WOT conditions 25 Exhaust sulphur smell 26 Intermittent concerns 27 Constant voltage x F1-71 CONTINUED Water and anti-freeze mixed improperly Charging system malfunction Improper engine compression Improper engine coolant level Improper engine oil viscosity Improper engine oil level Improper valve timing Low or dead battery Hydrolocked engine Improper dipstick Base engine malfunction Flywheel seized . thermostat.REPAIR MANUAL PAGES.BACK.INDEX RANG. hoses.CHAPTER. overflow system.TO.) Starter circuit including ignition switch open Improper tension or damaged drive belts Troubleshooting item 1 Melting of main or other fuses 2 Will not crank 3 Hard to start/long crank/erratic start/erratic crank 4 Engine stalls After start/at idle 5 Cranks normally but will not start 6 Slow return to idle 7 Engine runs rough/rolling idle 8 Fast idle/runs on 9 Low idle/stalls during deceleration Engine stalls/quits Engine runs rough Misses 10 Buck/jerk Acceleration/cruise Acceleration/cruise Acceleration/cruise Acceleration/cruise/ deceleration Acceleration Acceleration/cruise Acceleration/cruise Acceleration/cruise x x x x X X x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x X x x x x x x x x Hesitation/stumble Surges 11 Lack/loss of power 12 Knocking/pinging 13 Poor fuel economy 14 Emissions compliance 15 High oil consumption/leakage 16 Cooling system concerns Overheating 17 Cooling system concerns Runs cold 18 Exhaust smoke 19 Fuel odor (in engine compartment) 20 Engine noise 21 Vibration concerns (engine) 22 A/C does not work sufficiently. FROM.

g. mis-routing) Air leakage from intake-air system (Tubes looseness. A/C is always on/A/C compressor runs 23 continuously 24 A/C is not cut off under WOT conditions 25 Exhaust sulphur smell 26 Intermittent concerns 27 Constant voltage x x Overheating Runs cold x x x x x x x 19 Fuel odor (in engine compartment) x x x x F1-72 CONTINUED CMP sensor damaged (e.TO. FROM. open. gaskets broken) Initial ignition timing misadjustment (CMP & crankshaft pulley misadjustment Ignition coil malfunction (e.g.INDEX RANG. open or short circuits) x x x x x x x x x x x x Accelerator cable free play misadjustment Air cleaner element clogged or restriction Cooling fan seated improperly IAC valve improper operation Throttle body malfunction Spark plug malfunction Engine overheating Fuel quality . low resistance) x x x x x x x x Troubleshooting item 1 Melting of main or other fuses 2 Will not crank 3 Hard to start/long crank/erratic star/erratic crank 4 Engine stalls After start/at idle 5 Cranks normally but will not start 6 Slow return to idle 7 Engine runs rough/rolling idle 8 Fast idle/runs on 9 Low idle/stalls during deceleration Engine stalls/quits Engine runs rough Misses 10 Buck/jerk Hesitation/stumble Surges 11 Lack/loss of power 12 Knocking/pinging 13 Poor fuel economy Acceleration/cruise Acceleration/cruise Acceleration/cruise Acceleration/cruise/ deceleration Acceleration Acceleration/cruise Acceleration/cruise Acceleration/cruise x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x 14 Emissions compliance 15 High oil consumption/leakage 16 Cooling system concerns 17 Cooling system concerns 18 Exhaust smoke 20 Engine noise 21 Vibration concerns (engine) 22 A/C does not work sufficiently.INDEX TROUBLESHOOTING Possible factor Vacuum leakage (Vacuum hose damaged. open short or cracks) High-tension leads malfunction (Cracks . MANUAL TO.CHAPTER.BACK. MODEL .REPAIR MANUAL PAGES. crack.DRFT.

inoperative) PRC solenoid valve improper operation V-reference supply circuit malfunction Improper air/fuel mixture ratio control Exhaust system restricted or clogged Fuel hoses restricted or clogged Fuel filters restricted or clogged Catalytic converter malfunction Pressure regulator malfunction ECT sensor malfunction PCV valve malfunction Troubleshooting item Melting of main or other fuses Will not crank 1 2 x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x Hard to start/long crank/erratic start/erratic crank 3 After start/at idle Engine stalls 4 Cranks normally but will not start Slow return to idle Engine runs rough/rolling idle Fast idle/runs on Low idle/stalls during deceleration Acceleration/cruise Acceleration/cruise Acceleration/cruise Acceleration/cruise/ deceleration Acceleration Acceleration/cruise Acceleration/cruise Acceleration/cruise Poor fuel economy Emissions compliance High oil consumption/leakage Overheating Runs cold Cooling system concerns Cooling system concerns Engine stalls/quits Engine runs rough Misses Buck/jerk Hesitation/stumble Surges Lack/loss of power Knocking/pinging 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 10 5 6 7 8 9 x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x Exhaust smoke Fuel odor (in engine compartment) Engine noise Vibration concerns (engine) A/C does not work sufficiently. MANUAL TO. MODEL . A/C is always on/A/C compressor runs continuously A/C is not cut off under WOT conditions x x x x x x x x x Exhaust sulphur smell Intermittent concerns Constant voltage CONTINUED F1-73 .CHAPTER.INDEX RANG. FROM.INDEX TROUBLESHOOTING Fuel pump body malfunction (Mechanical or electrical Possible factor Fuel leakage from fuel system (Including insulator.TO.REPAIR MANUAL PAGES.BACK. injector O-ring) Evaporative emission control system malfunction Main relay malfunction (Mechanical or electrical) Injectors malfunction (Leakage or clogging.DRFT.

MANUAL TO.DRFT.REPAIR MANUAL PAGES. 23 A/C is always on/A/C compressor runs continuously x x x x x x x x x x x x x x x x x overheating runs cold x x 24 A/C is not cut off under WOT conditions 25 Exhaust sulphur smell 26 Intermittent concerns 27 Constant voltage CONTINUED F1-74 Suspension malfunction Drive line malfunction Clutch slippage Brake dragging Loose parts .INDEX TROUBLESHOOTING Neutral or clutch switch and related circuit malfunction Possible factor TP sensor misadjustment (Including looseness) Variable resistor and related circuit malfunction (Except Europe) A/C relay (A/C control signal) circuit malfunction Brake switch and related circuit malfunction MAF sensor and related circuit malfunction PSP switch and related circuit malfunction TP sensor and related circuit malfunction Improper refrigerant charging amount VSS and related circuit malfunction Wheels and tires improper balance Improper ATF level Troubleshooting item 1 Melting of main or other fuses 2 Will not crank 3 Hard to start/long crank/erratic start/erratic crank 4 Engine stalls after start/at idle 5 Cranks normally but will not start 6 Slow return to idle 7 Engine runs rough/rolling idle 8 Fast idle/runs on 9 Low idle/stalls during deceleration Engine stalls/quits Engine runs rough Misses 10 Buck/jerk Hesitation/stumble Surges 11 Lack/loss of power 12 Knocking/pinging 13 Poor fuel economy acceleration/cruise acceleration/cruise acceleration/cruise acceleration/cruise/ deceleration acceleration acceleration/cruise acceleration/cruise acceleration/cruise x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x 14 Emissions compliance 15 High oil consumption/leakage 16 Cooling system concerns 17 Cooling system concerns 18 Exhaust smoke 19 Fuel odor (in engine compartment) 20 Engine noise 21 Vibration concerns (engine) 22 A/C does not work sufficiently.TO.INDEX RANG.BACK. MODEL . FROM.CHAPTER.

CHAPTER.TO. FROM.INDEX SYMPTOM TROUBLESHOOTING: Symptom 1-Melting of main or other fuses Symptom 2-Will not crank Symptom 3-Hard to start/long crank/erratic crank Symptom 4-Engine stalls-after start/at idle Symptom 5-Cranks normally but will not start Symptom 6-Slow return to idle Symptom 7-Engine runs rough/rolling idle Symptom 8-Fast idle/runs on Symptom 9-Low idle/stalls during deceleration Symptom 10-Engie stalls/quits-acceleration/cruise .Hesitation/stumble – acceleration .INDEX RANG.Misses-acceleration/cruise .BACK.Buck/jerk – acceleration/cruise/deceleration .Surges – acceleration/cruise Symptom 11-Lack/loss of power-acceleration/cruise Symptom 12-Knocking/pinging-acceleration/cruise Symptom 13-Poor fuel economy Symptom 14-Emission compliance Symptom 15-High oil consumption/leakage Symptom 16-Cooling system concerns-overheating Symptom 17-Cooling system concerns-runs cold Symptom 18-Exhaust smoke Symptom 19-Fuel odor (in engine compartment) Symptom 20-Engine noise Symptom 21-Vibration concerns (engine) Symptom 22-A/C does not work sufficiently Symptom 23-A/C is always on (a/c compressor runs continuously Symptom 24-A/C does not cut off under wide open throttle (wot) conditions Symptom 25-Exhaust sulphur smell Symptom 26-Intermittent concerns Symptom 27-Constant voltage FI-91-93 FI-94-96 FI-97 FI-98-99 FI-100-101 FI-101 FI-102-103 FI-103 FI-104-105 FI-106 FI-107 FI-107 FI-108 FI-109 FI-110 FI-111 FI-112 FI-113-114 FI-75 FI-76 FI-77-78 FI-79-81 FI-82-84 FI-85 FI-86-88 FI-89 FI-90 CONTINUED . MANUAL TO.REPAIR MANUAL PAGES. MODEL .Engine runs rough – acceleration/cruise .DRFT.

INDEX RANG.TO. MANUAL TO.DRFT.BACK.CHAPTER.INDEX TROUBLESHOOTING SYMPTOM TROUBLESHOOTING SYMPTOM 1 MELTING OF MAIN OR OTHER FUSES Damaged Fuse MAIN (80 A) HEAD (30 A) A/C (10A) WIPER (15 A) STOP (15 A) FUEL INJ (30 A) ROOM (10 A) ENGINE (15 A) Related Wiring Harness MAIN fuse Generator Ignition switch Starter Ignition coil Condenser HEAD fuse • Generator A/C relay • Generator WIPER fuse • A/C relay • A/C switch STOP fuse • Brake switch Main relay • Fuel injector • PCM • PRC solenoid valve • Purge solenoid valve • IAC valve • MAF sensor • CMP sensor ROOM fuse • PCM ENGINE fuse • Main relay • Fuel pump relay Fuel pump relay • Fuel pump METER fuse • PCM METER (15 A) CONTINUED F1-75 . MODEL . FROM.REPAIR MANUAL PAGES.

TO. Retrieve any DTC. STARTER INSPECTION Is starting system okay? Do any other electrical accessories work? Yes No Yes Go to next step. FLYWHEEL.INDEX RANG. return to diagnostic index to service any additional symptoms. CHARGING SYSTEM. Go to next step. • Fuses Are all items okay? 2 3 Is clicking sound heard from starter when ignition switch is turned to START? Inspect starting system. GENERATOR INSPECTION No DTC is displayed: Inspect following: • START circuit in ignition switch • Open circuit between ignition switch and starter DTC is displayed: Go to appropriate DTC test. CONTINUED F1-76 . If okay. • Open or poor GND circuit at PCM • Poor connection of vehicle body GND No Yes No 4 5 Connect NGS tester to DLC. • Battery condition Repeat Step 1. FROM. Inspect for seized/hydrolocked engine or flywheel. Is "NO CODES RECEIVED" or "SYSTEM PASSED" displayed? Yes No 6 Verify test results. Communication error message is displayed: Inspect for following: • Open circuit between main relay and PCM terminal 1B • Open main relay GND circuit • Main relay is stuck open. • Open circuit between ignition switch and starter POSSIBLE • Starter malfunction CAUSE • Seized/hydrolocked engine or flywheel STEP INSPECTION RESULTS ACTION 1 Inspect for following: Yes Go to next step.INDEX TROUBLESHOOTING SYMPTOM 2 WILL NOT CRANK DESCRIPTION • Starter does not work. Turn ignition switch on.REPAIR MANUAL PAGES. • Battery connection No Service as necessary. Go to Step 4. ☞ Section H.DRFT. MANUAL TO.CHAPTER. ☞ Section G.BACK. MODEL . Inspect charging system. STARTING SYSTEM. ☞ Section G. FLYWHEEL INSPECTION Repair or replace components as required.

Go to next step. winter/summer blend) • Loose bands on intake-air system • Cracks on intake-air system parts • Air cleaner restriction Are all items okay? Connect NGS tester to DLC.CHAPTER. Battery in normal condition. Replace malfunctioning parts. Spark plug is wet or covered with carbon: Inspect for fuel leakage from fuel injector.TO. Is "NO CODES RECEIVED" or "SYSTEM PASSED" displayed? Is engine overheating? RESULTS Yes Go to next step. To prevent this. Retrieve any DTC. 2 Yes No Yes No No DTC is displayed: Go to next step.16 for "Cooling system concerns . MODEL .INDEX TROUBLESHOOTING SYMPTOM 3 DESCRIPTION HARD TO START/LONG CRANK/ERRATIC START/ERRATIC CRANK • • • • • • • • • • • • • • Starter cranks engine at normal speed but engine requires excessive cranking time before starting. causing serious injury and damage. Spark leakage from high-tension leads Vacuum leakage Poor fuel quality Starting system malfunction Spark plug malfunction Air leakage from intake-air system Erratic signal from CMP sensor Air cleaner restriction PCV valve malfunction Inadequate fuel pressure Purge solenoid valve malfunction MAF sensor contamination Restriction in exhaust system Pressure regulator control (PRC) system malfunction POSSIBLE CAUSE Warning Following troubleshooting flowchart contains fuel system diagnosis and repair procedures. proper octane. Repair suspected high-tension leads. ACTION No Service as necessary. always complete "BEFORE REPAIR PROCEDURE" and "AFTER REPAIR PROCEDURE" described in this manual. Go to next step. Spark plug is grayish white: Inspect for clogged fuel injector. Is spark plug wet.Overheating". BEFORE REPAIR PROCEDURE ☞ FUEL SYSTEM.g. AFTER REPAIR PROCEDURE STEP 1 INSPECTION Inspect for following: • Vacuum leakage • Fuel quality (e. Go to symptom troubleshooting No. Replace PCV valve.DRFT. covered with carbon or grayish white? Yes No Yes No 6 7 Visually inspect CMP sensor. contamination.BACK. Go to next step. ☞ FUEL SYSTEM. Fuel can ignite and cause serious injuries or death and damage. Is CMP sensor okay? Remove PCV valve and inspect PCV valve. Go to next step. Read following warnings before performing fuel system service: • Fuel vapor is hazardous. Does PCV valve rattle? Yes No Yes No F1-77 CONTINUED . Are there any cracks on high-tension leads? Inspect spark plug conditions.REPAIR MANUAL PAGES. It can easily ignite. Go to next step. Turn ignition switch on. Install spark plugs on original cylinders. DTC is displayed: Go to appropriate DTC test. MANUAL TO. Fuel can also irritate skin and eyes. • Fuel line spills and leaks are dangerous. 3 4 5 Inspect for cracks on high-tension leads. Always keep sparks and flames away from fuel. FROM.INDEX RANG.

Inspection Inspect PRC solenoid valve and related vacuum hose Turn ignition switch on. If it does not change.21 psi} for 5 min. Is starting system normal? Verify test results.INDEX RANG. Go to next step. If condition is not okay. 39—45 psi} Inspect pressure regulator for high pressure cause. Inspect exhaust system.7—3.CHAPTER. Is there any contamination? Is there restriction in exhaust system? Yes No Go to next step. ENGINE SYSTEM Inspect for fuel leakage inside pressure regulator. If condition is okay. MANUAL TO. and fuel distributor. Start engine. Go to next step. return to diagnostic index to service any additional symptoms. Start engine. Inspect for open fuel pump relief valve. INSPECTION. Is starting condition improved? Inspect for contaminated MAP sensor.INDEX TROUBLESHOOTING STEP INSPECTION RESULTS ACTION 8 Install fuel pressure gauge between fuel filter Yes Go to next step. Go to next step. Inspect if purge solenoid valve sticks to open. No Zero or low: Connect a jumper wire between F/P terminal at Inspect fuel pump circuit. Is fuel line pressure correct? High: Fuel line pressure 270—310 kPa {2. Connect vacuum hose to pressure regulator.DRFT. replace pressure regulator. inspect vacuum line. replace pressure regulator.2 kgf/cm 2. 3 psi} while driving vehicle? Connect vacuum hose to pressure regulator. If okay. Does fuel pressure gauge reading increase as vacuum gauge reading decreases and/or fuel pressure gauge reading decrease as vacuum gauge reading increases? Disconnect a vacuum hose from purge solenoid valve and plug opening end of vacuum hose. Inspect pressure regulator diaphragm condition.BACK. CONTINUED F1-78 . Verify fuel pressure gauge reading changes as vacuum changes. Replace MAP sensor. ☞ TROUBLESHOOTING. Go to next step. Start engine. Disconnect vacuum hose from pressure regulator and plug hose. 10 Yes No Inspect for clogged fuel filter. Start engine. 9 Is fuel line pressure held after ignition switch is turned off? Fuel line pressure More than 150 kPa {1. Yes Inspect for loose connectors or poor terminal contact. STARTING SYSTEM.21 kgf/cm . FROM. 11 Yes No Go to next step.5 kgf/cm 2.TO.REPAIR MANUAL PAGES. MODEL . ☞ Section G. Fuel Line Pressure Inspect for clogged main fuel line. Install vacuum gauge to intake manifold. If it changes. STARTER INSPECTION No Repair or replace components as required. Does fuel line pressure remain within ± 20 kPa 2 {0. and harnesses. DLC in engine compartment and GND. Inspect for clogged fuel return line. 12 Yes No Yes No Yes No 13 14 15 16 Inspect starting system. inspect fuel injector.

Disconnect TP sensor connector. ☞ FUEL SYSTEM. causing serious injury and damage. FROM. • Fuel line spills and leaks are dangerous. ACTION No Service as necessary.CHAPTER. Fuel can also irritate skin and eyes.INDEX TROUBLESHOOTING SYMPTOM 4 DESCRIPTION ENGINE STALLS . It can easily ignite. AFTER REPAIR PROCEDURE STEP INSPECTION Verify following: 1 • Vacuum connection • Air cleaner element • No air leakage from intake-air system • No restriction of intake-air system • Proper sealing of intake manifold and components attached to intake manifold (e. Measure voltage at TP sensor connector VREF terminal with ignition switch on.5—5.BACK.TO. contamination.AFTER START / AT IDLE • • • • • • • • • • • • • • • • • • • • • Engine stops unexpectedly at idle and/or after start. Air leakage from intake-air system parts Purge solenoid valve malfunction Improper operation of IAC valve No signal from CMP sensor due to sensor related wire or wrong installation Vacuum leakage Low engine compression Spark leakage from high-tension leads Poor fuel quality PCV valve malfunction Air cleaner restriction Restriction in exhaust system Electrical connector disconnection Open or short circuit in fuel pump body and related harness No battery power supply to PCM or poor GND Inadequate fuel pressure Fuel pump body mechanical malfunction Fuel leakage from fuel injector Fuel injector clogging Pressure regulator control (PRC) system malfunction POSSIBLE CAUSE Warning Following troubleshooting flowchart contains fuel system diagnosis and repair procedures. Yes Go to next step. Always • keep sparks and flames away from fuel. Read following warnings before performing fuel system service: • Fuel vapor is hazardous. To prevent this.DRFT. MODEL .5 V Is voltage okay? RESULTS Yes Go to next step.g.g.INDEX RANG. No Go to symptom troubleshooting No. winter/summer blend) • Electrical connections • Smooth operation of throttle valve Are all items okay? 2 Turn ignition switch on. Fuel can ignite and cause serious injuries or death • and damage.REPAIR MANUAL PAGES. Voltage 4. BEFORE REPAIR PROCEDURE ☞ FUEL SYSTEM.27 "Constant voltage". IAC valve) • Ignition wiring • Fuel quality (e. A/C system operation is improper. always complete "BEFORE • REPAIR PROCEDURE" and "AFTER REPAIR PROCEDURE" described in this manual. Repeat Step 11. MANUAL TO. CONTINUED F1-79 . proper octane.

Spark plug is grayish white: Inspect for clogged fuel injector. Install spark plugs on original cylinders. Go to next step.TO. Is spark plug wet. DTC Is displayed: Go to appropriate DTC test.INDEX RANG. 2B or 2C) • Poor connection of vehicle body GND Inspect IAC valve and wiring harness. go to Step 14. or grayish white? Yes No 10 11 Remove and shake PCV valve.CHAPTER. Retrieve any DTC. If symptom occurs with A/C on. go to next step. Go to next step.DRFT. Is "NO CODES RECEIVED" or SYSTEM PASSED" displayed? RESULTS Yes No No DTC is displayed: Go to next step. FROM. Go to next step.INDEX TROUBLESHOOTING STEP 3 INSPECTION Connect NGS tester to DLC. Does engine run smoothly at part throttle? Connect NGS tester to DLC. ACTION 4 5 Attempt to start engine at part throttle. Go to next step.BACK. Go to next step. Access RPM PID. Go to next step. Does PCV valve rattle? Is there any restriction in the exhaust system? Yes No Yes No CONTINUED F1-80 . Repair suspected high-tension lead. Turn ignition switch on. Is CMP sensor okay? Inspect for cracks on high-tension leads Are there any cracks on high-tension leads? Is strong blue spark visible at each disconnected high-tension lead while cranking engine? Yes No Yes No Yes No 9 Inspect spark plug condition. Inspect for following: • Open or short circuit In CMP sensor • Open or short circuit between CMP sensor and PCM terminal 2E • Open or short circuit in CMP sensor harnesses If CMP sensor and harness okay. Communication error message is displayed: Inspect for following: • Open circuit between main relay and PCM terminal 1B • Open main relay GND circuit • Main relay stuck open • Open PCM GND circuit (terminal 2A. Replace PCV valve. Go to next step. covered with carbon. MANUAL TO. Go to next step.REPAIR MANUAL PAGES. Inspect for following: • Open or short circuit in ignition coil • Open circuit in high-tension leads • Open circuit between igniter connector GND terminal and body GND • Open circuit between ignition switch and ignition coil • Open circuit between ignition coil and condenser • Open circuit between condenser and igniter • Open circuit between ignition coil and igniter • Open circuit between igniter and PCM terminal 2F Spark plug is wet or covered with carbon: Inspect for fuel leakage from injector. Replace malfunctioning parts. MODEL . Inspect exhaust system. Is RPM PID indicating engine speed during cranking of engine? Yes No Yes No 6 7 8 Visually inspect CMP sensor.

MANUAL TO. Inspect for open fuel pump relief valve.5 kgf/cm 2. return to diagnostic index to service any additional symptoms.7—3.INDEX RANG. For other symptoms. Turn A/C on and measure low side and high side pressure. 39—45 psi} RESULTS Yes Go to next step.TO. Inspect valve timing. inspect following: • Refrigerant charging amount 15 Yes Inspect if purge solenoid valve sticks to open. High: Inspect pressure regulator for high pressure cause. If condition is not okay. Repair or replace.DRFT. REFRIGERANT PRESSURE CHECK Is pressure within specifications? Disconnect vacuum hose between purge solenoid valve and dynamic chamber from purge solenoid side. Plug opening end of vacuum hose. Is engine stall now eliminated? Is air leakage felt or heard at intake-air system components while racing engine to higher speed? Is engine compression correct? Yes No Inspect pressure regulator diaphragm condition. Does fuel line pressure hold after ignition switch is turned off? Fuel line pressure More than 150 kPa {1. Connect pressure gauges to A/C low and high pressure side lines. Is fuel line pressure correct with ignition switch on? Fuel line pressure 270—310kPa {2.CHAPTER. go to next step. Turn ignition switch on. inspect fuel injector. go to symptom troubleshooting No. Inspect for clogged main fuel line. If condition is okay. Inspect for clogged fuel return line. Go to next step. 13 14 Visually inspect for fuel leakage at fuel injector.INDEX TROUBLESHOOTING STEP INSPECTION 12 Install fuel pressure gauge between fuel main pipe and fuel distributor. MODEL .BACK. and fuel line.2 kgf/cm 2. O-ring. related vacuum hose and related harnesses. ☞ Section U. Inspect for cause. Note • The following test is for stall concerns with A/C on. CONTINUED F1-81 . Service as necessary. Go to next step. Go to next step. No Yes No Yes No 16 17 18 Verify test results. Connect jumper wire between F/P terminal at DLC and GND. No If A/C is always on. replace pressure regulator. No ACTION Zero or low: Inspect fuel pump circuit. If other symptoms exist. If okay.21 psi} for 5 min. Yes Go to next step. Inspect PRC solenoid valve.REPAIR MANUAL PAGES. Inspect evaporative emission control system.23 "A/C is always on / A/C compressor runs continuously". Inspect for fuel leakage inside pressure regulator. REFRIGERANT SYSTEM SERVICE PROCEDURE. FROM. Start engine.

Refer to "Engine stalls" if this symptom appears after engine stall.INDEX TROUBLESHOOTING SYMPTOM 5 CRANKS NORMALLY BUT WILL NOT START • • • • • • • • • • • • • • • • • • • • • • • • Starter cranks engine at normal speed but engine will not run. FUEL SYSTEM. winter/summer blend) • No air leakage from intake-air system • Proper sealing of intake manifold and components attached to intake manifold (e.REPAIR MANUAL PAGES. IAC valve) • Ignition wiring • Electrical connections • Fuses • Smooth operation of throttle valve Are all items okay? RESULTS Yes Go to next step.g. alarm etc. Fuel can ignite and cause serious injuries or death and damage. Purge solenoid valve malfunction Pressure regulator control (PRO) system malfunction DESCRIPTION POSSIBLE CAUSE Warning Following troubleshooting flowchart contains fuel system diagnosis and repair procedures.INDEX RANG. ACTION No Service as necessary. Always keep sparks and flames away from fuel. CONTINUED F1-82 . MODEL .TO. No battery power supply to PCM Air leakage from intake-air system Open PCM GND or vehicle body GND Improper operation of IAC valve No signal from CMP sensor due to sensor related wire or incorrect installation Low engine compression Vacuum leakage Spark leakage from high-tension leads Poor fuel quality PCV valve malfunction Air cleaner restriction Restriction in exhaust system Disconnected electrical connector Open or short circuit in fuel pump body and related harness Inadequate fuel pressure Fuel pump body mechanical malfunction Fuel leakage from injector Fuel injector is clogged.DRFT. BEFORE REPAIR PROCEDURE FUEL SYSTEM. Fuel line spills and leaks are dangerous. proper octane. contamination.) • Fuel quality (e. Repeat Step 11. causing serious injury and damage. FROM. It can easily ignite.CHAPTER.BACK. To prevent this.g. Fuel can also irritate skin and eyes. Read following warnings before performing fuel system service: • • ☞ ☞ STEP 1 Fuel vapor is hazardous. always complete "BEFORE REPAIR PROCEDURE" and "AFTER REPAIR PROCEDURE" described In this manual. AFTER REPAIR PROCEDURE INSPECTION Verify following: • Vacuum connection • External fuel shut off or accessory (kill switch. MANUAL TO. Fuel in tank. Battery in normal condition.

Access RPM PID. MANUAL TO. Inspect for following: • Open or short circuit in ignition coil • Open circuit in high-tension leads • Open circuit between igniter connector GND terminal and body GND • Open circuit between ignition switch and ignition coil • Open circuit between ignition coil and condenser • Open circuit between condenser and igniter • Open circuit between ignition coil and igniter • Open circuit between igniter and PCM terminal 2F If spark plug is wet or covered with carbon. Disconnect TP sensor connector. ACTION 3 Turn ignition switch on. Install spark plugs on original cylinders.CHAPTER. Turn ignition switch on. Go to next step. covered with carbon. Repair suspected high-tension leads. Go to next step. Go to next step. Go to next step. Replace PCV valve. Go to next step.INDEX RANG. MODEL . Is RPM PID indicating engine speed when cranking engine? Yes No Go to symptom troubleshooting No.5—5. Measure voltage at TP sensor connector VREF terminal with ignition switch on. Is CMP sensor okay? Inspect for cracks on high-tension leads. Is there any cracks on high-tension leads? Is strong blue spark visible at each disconnected high-tension lead while cranking engine? Yes No Yes No Yes No 10 Inspect spark plug conditions. Inspect for following: • Open or short circuit in CMP sensor • Open or short circuit between CMP sensor and PCM terminal 2E • Open or short circuit in CMP sensor harnesses If CMP sensor and harness are okay. Retrieve any DTC.DRFT.5 V Is voltage okay? Does engine start with throttle closed? Will engine start and run smoothly at part throttle? Connect NGS tester to DLC.TO. Go to next step.27 "Constant voltage". Does PCV valve rattle? Is there any restriction in exhaust system? Yes No Yes No F1-83 CONTINUED . FROM. Voltage 4. 2B or 2C) • Poor connection of vehicle body GND Go to next step.INDEX TROUBLESHOOTING STEP 2 INSPECTION Connect NGS tester to DLC. Inspect exhaust system. Go to next step. Go to next step. or grayish white? Yes No 11 12 Remove and shake PCV valve. go to next step. 4 5 6 Yes No Yes No Yes No Go to Step 18. Go to next step. 7 8 9 Visually inspect CMP sensor. Communication error message is displayed: Inspect for following: • Open circuit between main relay and PCM terminal 1B • Open main relay GND circuit • Main relay stuck open • Open PCM GND circuit (PCM terminal 2A. If spark plug is grayish white. Is spark plug wet. inspect for fuel leakage from injector. DTC is displayed: Go to appropriate DTC test. Inspect IAC valve and wiring harness.BACK. Replace malfunctioning parts.REPAIR MANUAL PAGES. inspect for clogged fuel injector. Is "NO CODES RECEIVED" or "SYSTEM PASSED" displayed? RESULTS Yes No No DTC is displayed: Go to next step.

16 17 18 Verify test results.BACK. No Yes No Yes No Go to next step.2 kgf/cm 2. Is starting condition improved? Is air leakage felt or heard at intake-air system components while racing engine to higher speed? Is engine compression correct? Yes Go to next step. No Zero or low: Connect jumper wire between F/P terminal at Inspect fuel pump circuit.DRFT. If condition is okay.CHAPTER. Start engine. Go to next step. Is fuel line pressure correct when ignition switch Inspect for clogged main fuel line. If okay. DLC in engine compartment and GND. return to diagnostic index to service any additional symptoms. CONTINUED F1-84 . replace pressure regulator. 39—45 psi} Inspect for clogged fuel return line. 15 Yes Inspect if purge solenoid valve sticks to open mechanically. High: 270—3-10 kPa Inspect pressure regulator for high pressure cause. If condition is not okay.INDEX TROUBLESHOOTING STEP INSPECTION RESULTS ACTION 13 Install fuel pressure gauge between fuel main Yes Go to next step. Inspect evaporative emission control system. Is fuel line pressure held after ignition switch is turned off? Fuel line pressure More than 150 kPa {1. FROM. Plug opening end of vacuum hose. Inspect for causes. Repair or replace. Inspect for fuel leakage inside pressure regulator. MANUAL TO. is cycled on/off five times? Inspect PRC solenoid. related vacuum hose.5 kgf/cm 2. Disconnect vacuum hose between purge solenoid valve and dynamic chamber from purge solenoid valve side. Inspect for open fuel pump relief valve. Inspect valve timing.INDEX RANG. and harFuel line pressure nesses.TO. inspect fuel injector. MODEL . No Inspect pressure regulator diaphragm condition. Turn ignition switch on. 21 psi} for 5 min. {2.7—3. 14 Visually inspect for fuel leakage at fuel injector O-ring and fuel line.REPAIR MANUAL PAGES. Service as necessary. pipe and fuel distributor.

Throttle body malfunction Air leakage from intake-air system INSPECTION Connect NGS tester to DLC. If temperature gauge on instrument cluster indicates cold range but ECT V PID is normal. MODEL . THERMOSTAT. Inspect for both ECT V PID and temperature gauge on instrument cluster readings.DRFT. Turn ignition switch on.INDEX RANG. FROM. inspect ECT sensor. Retrieve any DTC. If temperature gauge on instrument cluster indicates normal range but ECT V PID is not same as temperature gauge reading. • • • • ECT sensor malfunction Thermostat is stuck open. If okay. Access ECT V PID on NGS tester. Clean or replace throttle body.TO. Go to next step.REPAIR MANUAL PAGES. MANUAL TO. Inspect for air leakage from intake-air system components while racing engine to higher speed. inspect temperature gauge and heat gauge unit. Engine coolant temperature and thermostat are okay. ACTION 2 3 Is throttle body free of contamination? Yes No 4 Verify test results. CONTINUED F1-85 .CHAPTER.INDEX TROUBLESHOOTING SYMPTOM 6 DESCRIPTION POSSIBLE CAUSE STEP 1 SLOW RETURN TO IDLE • Engine takes more time than normal to return to idle speed. THERMOSTAT INSPECTION Is thermostat okay? RESULTS Yes No Yes No No DTC is displayed: Go to next step.BACK. DTC is displayed: Go to appropriate DTC test. Is "NO CODES RECEIVED" or "SYSTEM PASSED" displayed? Remove thermostat and inspect operation. ☞ Section E. return to diagnostic index to service any additional symptoms.

TO. Go to next step. Fuel can ignite and cause serious injuries or death and damage. ☞ FUEL SYSTEM. causing serious injury and damage. contamination. winter/summer blend) • No air leakage from intake-air system • Proper sealing of intake manifold and components attached to intake manifold (e. Go to symptom troubleshooting No.DRFT. Air leakage from intake-air system parts A/C system operation is improper. MODEL . Idle speed is too slow and engine shakes excessively. Always keep sparks and flames away from fuel. Read following warnings before performing fuel system service: • Fuel vapor is hazardous.Overheating". always complete "BEFORE REPAIR PROCEDURE" and "AFTER REPAIR PROCEDURE" described in this manual. Repeat Step 1. No Yes No DTC is displayed: Go to appropriate DTC test.CHAPTER.INDEX TROUBLESHOOTING SYMPTOM 7 DESCRIPTION ENGINE RUNS ROUGH/ROLLING IDLE • • • • • • • • • • • • • • • • • • • • • Engine speed fluctuates between specified idle speed and lower speed and engine shakes excessively.16 "Cooling system concerns .g. Turn ignition switch on. Is "NO CODES RECEIVED" or "SYSTEM PASSED" display? Is engine overheating? RESULTS Yes Go to next step. Are all items okay? Connect NGS tester to DLC. To prevent this. Spark leakage from high-tension leads Purge solenoid valve malfunction (if equipped) Improper operation of IAC valve Low engine compression Erratic signal from CMP sensor Poor fuel quality PCV valve malfunction Air cleaner restriction Restriction in exhaust system Disconnected electrical connectors Inadequate fuel pressure Fuel pump body mechanical malfunction Fuel leakage from fuel injector Fuel injector clogging Engine overheating Vacuum leakage Pressure regulator control (PRC) system malfunction POSSIBLE CAUSE Warning Following troubleshooting flowchart contains fuel system diagnosis and repair procedures. 3 F1-86 CONTINUED . FROM. proper octane.g. • Fuel line spills and leaks are dangerous.BACK. MANUAL TO. Fuel can also irritate skin and eyes.INDEX RANG. Retrieve any DTC. 2 Yes No DTC is displayed: Go to next step. It can easily ignite. IAC valve) • Ignition wiring • Electrical connections • Fuses • Smooth operation of throttle valve. AFTER REPAIR PROCEDURE STEP 1 INSPECTION Verify following: • External fuel shut off or accessory • Fuel quality (e.REPAIR MANUAL PAGES. BEFORE REPAIR PROCEDURE ☞ FUEL SYSTEM. ACTION No Service as necessary.

DRFT. O-ring. MANUAL TO. Install spark plugs on original cylinders. Spark plug is grayish white: Inspect for clogged fuel injector. Repair suspected high-tension leads. Replace malfunctioning parts.6 kgf/cm 2.21 psi} for 5 min. 30—36 psi} Yes No Yes No 10 11 Visually inspect for fuel leakage at fuel injector. related vacuum hose and harnesses High • Inspect pressure regulator for high pressure cause • Inspect for clogged fuel return line Go to next step. Yes No Inspect pressure regulator diaphragm condition.INDEX TROUBLESHOOTING STEP 4 INSPECTION Note • Following test is for engine running rough idle with A/C on concerns. go to next step. Connect pressure gauge to A/C low and high pressure side lines. If other symptoms exist. or grayish white? RESULTS Yes Go to next step. replace pressure regulator. MODEL . Access PSP SW PID. REFRIGERANT SYSTEM SERVICE PROCEDURE. go to symptom troubleshooting No. Measure low side and high side pressures. go to next step. Go to next step. Go to next step. If other symptoms exist. Start engine and run it at idle. Inspect IAC valve and wiring harness. and fuel line.TO. Does fuel line pressure hold after ignition switch is turned off? Fuel line pressure 2 More than 150 kPa {1. No Go to next step. Spark plug is wet or covered with carbon: Inspect for fuel leakage from injector. Is PSP SW PID okay? Visually inspect CMP sensor. Zero or low Inspect fuel pump circuit Inspect for open fuel pump relief valve Inspect for fuel leakage inside pressure regulator Inspect for clogged main fuel line Inspect PRC solenoid valve. ACTION No If A/C is always on. Measure fuel line pressure at idle. If condition is okay. Start engine and run it at idle. Go to next step.BACK. No 9 Start engine and disconnect IAC valve connector. Inspect if PSP SW PID is on while turning steering wheel right to left. inspect fuel injector. CONTINUED F1-87 . covered with carbon. 6 7 8 Yes No Yes No Yes Go to next step. Go to next step. Is spark plug wet.REPAIR MANUAL PAGES.CHAPTER. Service as necessary. ☞ Section U. Does rpm drop or engine stall? Install fuel pressure gauge between fuel main pipe and fuel distributor. Start engine and run it at idle. Are there any cracks on high-tension leads? Inspect spark plug conditions.1—2. Is CMP sensor okay? Inspect for cracks on high-tension leads. For other symptoms. Turn A/C switch on. FROM.23 "A/C is always on / A/C compressor runs continuously". REFRIGERANT PRESSURE CHECK Are reading pressures within specification? Note • Following test is for engine running rough with P/S on.5 kgf/cm . If condition is not okay. inspect following: • Refrigerant charging amount 5 Yes Inspect power steering pressure switch operation and wiring harness between power steering pressure switch connector and PCM connector terminal 1P.INDEX RANG. Is fuel line pressure correct at idle? Fuel line pressure 210—250 kPa {2.

ACTION No Inspect and repair or replace faulty O2S. Start engine. Plug opening end of vacuum hose. MODEL . Does engine condition improve? Remove and shake PCV valve. Access FHO2S PID. Replace PCV valve. Does PCV valve rattle? Is there restriction in exhaust system? Is engine compression correct? RESULTS Yes Go to next step.DRFT. Inspect valve timing. Start the engine and run it at idle. MANUAL TO. 13 Yes Inspect if purge solenoid valve sticks open mechanically. then go to next step.REPAIR MANUAL PAGES. connector or terminal.CHAPTER.45 V during fuel cut: lean condition Disconnect vacuum hose between purge solenoid valve and dynamic chamber from purge solenoid valve side. FROM.45 V when accelerator pedal is suddenly depressed: rich condition • Less than 0.TO. Go to next step.INDEX RANG. return to diagnostic index to service any additional symptoms. harness. Inspect exhaust system. 14 15 16 17 Verify test results. Is FHO2S PID okay? • More than 0. If okay. No Yes No Yes No Yes No Go to next step. CONTINUED F1-88 .BACK.INDEX TROUBLESHOOTING STEP 12 INSPECTION Connect NGS tester to DLC. Inspect for causes. Inspect evaporative emission control system. Go to next step.

No DTC is displayed: Go to next step. DTC is displayed: Go to appropriate DTC test.TO. No Start and warm up engine to normal operating temperature. 2 Connect NGS tester to DLC.17 "Cooling system concerns . FROM. Is "NO CODES RECEIVED" or "SYSTEM PASSED" displayed? Is there air leakage felt or heard at intake-air system components while racing engine to higher speed? Yes No Yes No 3 4 Verify test results. Engine runs after ignition switch is turned off. return to diagnostic index to service any additional symptoms. Repair or replace parts as necessary.INDEX RANG. Verify accelerator cable free play. Is ECT PID reading between 112°C {234°F} and 82°C {180°F}? ACTION Go to next step. Turn ignition switch on. ECT PID is higher than 112°C {234°F}: Go to symptom troubleshooting No.INDEX TROUBLESHOOTING SYMPTOM 8 DESCRIPTION POSSIBLE CAUSE FAST IDLE/RUNS ON • • • • • Engine speed continues at fast idle after warm-up. MANUAL TO. MODEL .16 "Cooling system concerns .Runs cold".Overheating".CHAPTER.REPAIR MANUAL PAGES. ECT malfunction Air leakage from intake-air system Throttle body malfunction STEP INSPECTION RESULTS 1 Connect NGS tester to DLC. Retrieve any DTC. Yes Access ECT PID. CONTINUED F1-89 .BACK. If okay.DRFT. ECT PID is less than 82°C {180°F}: Go to symptom troubleshooting No.

return to diagnostic index to service any additional symptoms. Does engine condition improve? Connect NGS tester to DLC. MANUAL TO. NL SW PID: Inspect neutral switch and clutch switch. Go to next step. Vacuum leakage IAC valve malfunction Air leakage from intake-air system MAF sensor or related circuit malfunction TP sensor or related circuit malfunction Brake switch or related circuit malfunction Neutral/clutch switch or related circuit malfunction INSPECTION Does engine idle roughly? RESULTS Yes No 2 Verify following: • Proper routing and no damage of vacuum lines • IAC valve is connected properly. go to next step. Service as necessary. No DTC is displayed: Go to next step. MAF V PID: Inspect MAF sensor. Inspect following: • Circuit from IAC valve to PCM connector terminal 2W for open and short • IAC valve for sticking If okay. Plug opening end of vacuum hose. Retrieve any DTC. FROM. Go to next step.TO.INDEX RANG.DRFT. 7 Verify test results. Yes Access TP V. BRK SW and NL SW PIDs. • No air leakage from intake-air system Are all items okay? Connect NGS tester to DLC. DTC is displayed: Go to appropriate DTC test.7 for "Engine runs rough/Rolling idle". VS PID: Inspect VSS. Go to next step. Turn ignition switch on. BRK SW PID: Inspect brake switch. Monitor each PID while driving vehicle. TP V PID: Inspect TP sensor. POSSIBLE CAUSE STEP 1 3 Yes No Yes No 4 5 6 Disconnect vacuum hose between purge Yes solenoid valve and dynamic chamber from purge solenoid valve side.REPAIR MANUAL PAGES. Is "NO CODES RECEIVED" or "SYSTEM PASSED" displayed? Does idle speed drop or stall when disconnecting IAC valve? Yes No ACTION Go to symptom troubleshooting No. CONTINUED F1-90 . MAP V. Go to symptom troubleshooting No. PCM INSPECTION Go to next step. MODEL . If okay. Repeat Step 2.INDEX TROUBLESHOOTING SYMPTOM 9 DESCRIPTION LOW IDLE/STALLS DURING DECELERATION • • • • • • • • Engine stops unexpectedly at beginning of deceleration or recovery from deceleration.26 for "Intermittent concerns".BACK. Inspect evaporative emission control system. No Drive vehicle. No • TP V PID • MAF V PID • VS PID BRK • SW PID • NL SW PID Are PIDs okay? ☞ CONTROL SYSTEM. VS.CHAPTER.

• Engine stops unexpectedly while cruising. TP sensor and VSS • Clutch slippage Warning Following troubleshooting flowchart contains fuel system diagnosis and repair procedures. Read following warnings before performing fuel system service: • Fuel vapor is hazardous. Fuel can also irritate skin and eyes. MANUAL TO.TO.CHAPTER. • Air leakage from intake-air system parts • Purge solenoid valve malfunction • Improper operation of IAC valve • Erratic signal from CMP sensor • Low engine compression • Vacuum leakage • Poor fuel quality • Spark leakage from high-tension leads • Air cleaner restriction • PCV valve malfunction • Improper valve timing due to jumping out of timing belt • Restriction in exhaust system • Intermittent open or short in fuel pump circuit • Inadequate fuel pressure • Fuel pump mechanical malfunction • Fuel leakage from fuel injector • Fuel injector clogging • Intermittent open or short of MAF sensor. MODEL .BACK. winter/summer blend) • Electrical connections • Smooth operation of throttle valve Are all items okay? ACTION F1-91 CONTINUED .ACCELERATION/CRUISE ENGINE RUNS ROUGH .ACCELERATION SURGES . Fuel can ignite and cause serious injuries or death and damage.ACCELERATION/CRUISE MISSES . It can easily ignite. BEFORE REPAIR PROCEDURE FUEL SYSTEM. • Vehicle bucks/jerks during acceleration.ACCELERATION/CRUISE • Engine stops unexpectedly at beginning of acceleration or during acceleration. causing serious injury and damage.INDEX RANG. proper octane. To prevent this. always complete "BEFORE REPAIR PROCEDURE" and "AFTER REPAIR PROCEDURE" described in this manual.g.DRFT. AFTER REPAIR PROCEDURE STEP INSPECTION RESULTS Verify following: Go to next step. • Momentary pause at beginning of acceleration or during acceleration. • Ignition wiring Repeat Step 1. IAC valve) No Service as necessary.INDEX TROUBLESHOOTING ENGINE STALLS/QUITS . • Engine speed fluctuates during acceleration or cruising.ACCELERATION/CRUISE BUCK/JERK . • Engine misses during acceleration or cruising. contamination.ACCELERATION/CRUISE/DECELERATION HESITATION/STUMBLE . ☞ ☞ SYMPTOM 10 DESCRIPTION POSSIBLE CAUSE FUEL SYSTEM. • Momentary minor irregularity in engine output. FROM. 1 Yes • Vacuum connection • Air cleaner element • No air leakage from intake-air system • No restriction of intake-air system • Proper sealing of intake manifold and components attached to intake manifold (e.REPAIR MANUAL PAGES. • Fuel quality (e. cruising or deceleration. Always keep sparks and flames away from fuel.g. • Fuel line spills and leaks are dangerous. • A/C system operation is improper.

Are PIDs within specification? ☞ CONTROL SYSTEM. and fuel line. Replace PCV valve. Spark plug is wet or covered with carbon: Inspect for fuel leakage from fuel injector. Go to next step. Inspect for clogged fuel return line. Install spark plugs on original cylinders. Inspect exhaust system. Service as necessary. covered with carbon. Replace malfunctioning parts. ACTION 3 Yes No 4 Connect NGS tester to DLC. Go to next step. Go to next step. CONTINUED F1-92 .7—3. Yes No Yes No Yes No 10 Yes No 9 11 Yes No Inspect pressure regulator diaphragm condition. PCM INSPECTION Yes No 5 6 Visually inspect CMP sensor. RPM PID: Inspect CMP sensor and related harness for vibration. Inspect for open fuel pump relief valve. B+ PID. Go to next step. Go to next step. replace pressure regulator. DTC is displayed: Go to appropriate DTC test. Turn ignition switch on. and VS PID.TO.5 kgf/cm . Go to next step. Go to symptom troubleshooting No. Adjust as necessary. Retrieve any DTC.Overheating".BACK. If condition is not okay.INDEX RANG. inspect fuel injector. TP V PID: Inspect if output signal from TP sensor changes smoothly. If condition is okay. Inspect for fuel leakage inside pressure regulator. Is CMP sensor okay? Inspect spark plug condition. 21 psi} for 5 min. Inspect for clogged main fuel line. Go to next step. MAF V PID: Inspect for open circuit of MAF sensor and related wire harness intermittently. Connect jumper wire between F/P terminal at DLC in engine compartment and GND. MODEL . Access RPM PID.INDEX TROUBLESHOOTING STEP 2 INSPECTION Connect NGS tester to DLC. Is lever in correct position? Are there restrictions in the exhaust system? Install fuel pressure gauge between fuel main pipe and fuel distributor.DRFT. B+ PID: Inspect for open circuit intermittently. Go to next step. O-ring. 39—45 psi} Visually inspect for fuel leakage at fuel injector. Is fuel line pressure correct with ignition switch on? Fuel line pressure 270—310kPa {2.2 kgf/cm 2.CHAPTER. Spark plug is grayish white: Inspect for clogged fuel injector. Turn ignition switch on. Is "NO CODES RECEIVED" or "SYSTEM PASSED" displayed? Is engine overheating? RESULTS Yes No No DTC is displayed: Go to next step. MANUAL TO. Does PCV valve rattle? Verify that throttle lever is resting on throttle valve stop screw and/or throttle valve orifice plug. TP V PID.16 "Cooling system concerns . Is spark plug wet. VS PID: Inspect for open circuit of VSS and related wire harness intermittently. Go to next step.REPAIR MANUAL PAGES. FROM. Zero or low: Inspect fuel pump circuit. intermittent open/short circuit. High: Inspect pressure regulator for high pressure cause. Does fuel line pressure hold after ignition switch is turned off? Fuel line pressure 2 More than 150 kPa {1. or grayish white? Yes No Yes No 7 8 Remove and shake PCV valve. MAF V PID. • RPM PID • B+PID • TP V PID • MAF V PID • VS PID Drive vehicle while monitoring PIDs.

REFRIGERANT SYSTEM SERVICE PROCEDURES. vacuum reading increases? If it changes. If it does not change.BACK. Yes Go to next step. replace pressure regulator. REFRIGERANT PRESSURE CHECK Disconnect vacuum hose between purge solenoid valve and dynamic chamber from purge solenoid valve side.DRFT. No Connect vacuum hose to pressure regulator. FROM. CONTINUED F1-93 .INDEX RANG. inspect following: • Refrigerant charging amount 14 Yes Inspect if purge solenoid valve sticks open mechanically. Does fuel pressure gauge reading increase as Start engine. inspect vacuum line. Is pressure within specifications? ☞ Section U.CHAPTER. vacuum gauge reading decreases and/or does Verify that fuel pressure gauge reading changes as vacuum fuel pressure gauge reading decrease as changes. go to next step. No If A/C is always on. Drive vehicle.INDEX TROUBLESHOOTING STEP INSPECTION RESULTS ACTION 12 Install vacuum gauge to intake manifold. For other symptoms. go to symptom troubleshooting No. If other symptoms exist. No Yes Go to next step. Turn A/C on and measure low side and high side pressure.23 "A/C is always on / A/C compressor runs continuously". return to diagnostic index to service any additional symptoms. If okay.REPAIR MANUAL PAGES. Inspect following: • Valve timing • Clutch Inspect for cause. 13 Note • The following test is for engine stalling with A/C on. Connect a pressure gauge to A/C low and high pressure side lines. 15 No 16 Verify test results. MANUAL TO.TO. Inspect evaporative emission control system. Does engine condition improve? Is engine compression correct? Yes Go to next step. MODEL . Plug opening end of vacuum hose. Start engine.

Go to next step. Repeat Step 1. causing serious injury and damage. FROM. TP sensor and VSS Clutch slippage POSSIBLE CAUSE • • • • Warning Following troubleshooting flowchart contains fuel system diagnosis and repair procedures. AFTER REPAIR PROCEDURE STEP 1 INSPECTION Verify following: • Vacuum connection • Air cleaner element • No air leakage from intake-air system • No restriction of intake-air system • Proper sealing of intake manifold and components attached to intake manifold (e. 16 "Cooling system concerns .g.g.REPAIR MANUAL PAGES.Overheating".INDEX RANG. ☞ FUEL SYSTEM. Fuel can also irritate skin and eyes. power down when climbing hills). It can easily ignite.TO. proper octane.INDEX TROUBLESHOOTING SYMPTOM 11 DESCRIPTION LACK/LOSS OF POWER . DTC is displayed: Go to appropriate DTC test. Turn ignition switch on. Read following warnings before performing fuel system service: • Fuel vapor is hazardous.CHAPTER. To prevent this. always complete "BEFORE REPAIR PROCEDURE" and "AFTER REPAIR PROCEDURE" described in this manual. BEFORE REPAIR PROCEDURE ☞ FUEL SYSTEM. ACTION No Service as necessary. Retrieve any DTCs.DRFT.ACCELERATION/CRUISE • • • • • • • • • • • • • • • • • Performance is poor under load e. contamination. 2 Yes No Yes No No DTC Is displayed: Go to next step. MANUAL TO. Is "NO CODES RECEIVED" or "SYSTEM PASSED" displayed? Is engine overheating? RESULTS Yes Go to next step. • Fuel line spills and leaks are dangerous. Improper A/C system operation Air leakage from intake-air system parts Purge control solenoid malfunction Brake dragging Erratic signal from CMP sensor Low engine compression Vacuum leakage Poor fuel quality Spark leakage from high-tension leads Air cleaner restriction PCV valve malfunction Improper valve timing due to jumping out of timing belt Restriction in exhaust system Intermittent open or short in fuel pump circuit Inadequate fuel pressure Fuel pump mechanical malfunction Fuel leakage from fuel injector Fuel injector clogging Intermittent open or short of MAP sensor.g. MODEL . Fuel can ignite and cause serious injuries or death and damage.BACK. Go to symptom troubleshooting No. 3 CONTINUED F1-94 . winter/summer blend) Are all items okay? Connect NGS tester to DLC. IAC valve) • Fuel quality (e. Always keep sparks and flames away from fuel.

MAF V PID: Inspect for intermittent open circuit of MAF sensor and related wire harness. REFRIGERANT SYSTEM SERVICE PROCEDURES. Spark plug is wet or covered with carbon: Inspect for fuel leakage from fuel injector. and VS PID. Is the pressure within specifications? ☞ Section U. Go to next step. REFRIGERANT PRESSURE CHECK Inspect for A/C cut off operation. Is fuel line pressure correct with ignition switch on? Fuel line pressure 270—310 kPa {2. 39—45 psi} Install vacuum gauge to intake manifold.DRFT. Connect pressure gauge to A/C low and high side pressure lines. Inspect A/C cut-off system components. Turn ignition switch on. Does A/C cut-off work properly? Yes No Yes No Yes No 10 Yes No 11 Yes No If A/C is always on. MAF V PID.CHAPTER. If it changes. MANUAL TO.BACK.REPAIR MANUAL PAGES. Go to next step. Go to next step. go to symptom troubleshooting No. inspect following: • Refrigerant charging amount 12 Yes No Go to next step. MODEL .INDEX TROUBLESHOOTING STEP INSPECTION 4 Connect NGS tester to DLC. Verify that fuel pressure gauge reading changes as vacuum changes. Go to next step.2 kgf/cm 2. Spark plug is grayish white: Inspect for clogged fuel injector. Access RPM PID. Inspect for fuel leakage inside pressure regulator. PCM INSPECTION 5 6 Visually inspect CMP sensor.23 "A/C always on/ A/C compressor runs continuously". Replace malfunctioning parts. TP V PID: Inspect if TP sensor output increases smoothly. Does PCV valve rattle? Is there restriction in exhaust system? Install fuel pressure gauge between fuel main pipe and fuel distributor. Inspect for clogged fuel return line. No 7 8 9 Remove and shake PCV valve. Connect jumper wire between F/P terminal at DLC in engine compartment and GND. Are PIDs within specification? ☞ CONTROL SYSTEM. Turn A/C on and measure low side and high side pressure. Start engine. FROM. go to next step. Inspect exhaust system. Go to next step. Connect vacuum hose to pressure-regulator. Start engine. Zero or low: Inspect fuel pump circuit. Inspect for open fuel pump relief valve. Replace PCV valve. Install spark plugs on original cylinders. covered with carbon or grayish white? Yes No Yes RESULTS Yes Go to next step. Inspect for clogged main fuel line. If it does not change. inspect vacuum line. F1-95 CONTINUED . Is CMP sensor okay? Inspect spark plug conditions.TO. Is spark plug wet. • RPM PID • MAP V PID • TP V PID • VS PID Drive vehicle while monitoring PIDs. For other symptoms. TP V PID. Does fuel pressure gauge reading increase as vacuum gauge reading decreases and/or does fuel pressure gauge reading decrease as vacuum reading increases? Note • Following test is for engine stalling with A/C on concern. Go to next step. No ACTION RPM PID: Inspect CMP sensor and related harness for vibration and/or intermittent open/short circuit. replace pressure regulator. If other symptoms exist. Go to next step.INDEX RANG.7—3. High: Inspect pressure regulator for high pressure cause. VS PID: Inspect for intermittent open circuit of VSS and related wire harness.

Does engine condition improve? Is engine compression correct? RESULTS Yes ACTION Inspect if purge solenoid valve sticks open mechanically. Plug opening end of vacuum hose. MODEL .TO.DRFT. Inspect following: • Valve timing • Clutch • Brake system for dragging Inspect for cause.INDEX TROUBLESHOOTING STEP 13 INSPECTION Disconnect vacuum hose between purge solenoid valve and dynamic chamber from purge solenoid valve side. MANUAL TO. If okay. CONTINUED F1-96 .INDEX RANG.REPAIR MANUAL PAGES. Drive vehicle. Go to next step. return to diagnostic index to service any additional symptoms. No Yes 14 No 15 Verify test results. Inspect evaporative emission control system.BACK.CHAPTER. FROM.

BACK. It can easily ignite. Inspect for clogged main fuel line. CONTINUED F1-97 .1—2. always complete "BEFORE REPAIR PROCEDURE" and "AFTER REPAIR PROCEDURE" described in this manual. ACTION STEP 1 Connect NGS tester to DLC.6 kgf/cm 2.TO. 30—36 psi} 2 Yes No No DTC is displayed: Go to next step. BEFORE REPAIR PROCEDURE ☞ FUEL SYSTEM. Turn ignition switch on. Yes Start engine. return to diagnostic index to service any additional symptoms. Fuel can ignite and cause serious injuries or death and damage. To prevent this. Is ECT PID less than specification? Connect NGS tester to DLC. Is "NO CODES RECEIVED" or "SYSTEM PASSED" displayed? Is engine compression correct? Install fuel pressure gauge between fuel main pipe and fuel distributor. ☞ FUEL SYSTEM. High: Inspect pressure regulator for high pressure cause. Zero or low: Inspect fuel pump circuit. No Does fuel pressure gauge reading increase as vacuum gauge reading decreases and/or does fuel pressure gauge reading decrease as vacuum reading increases? 6 Verify test results. Inspect for clogged fuel return line.REPAIR MANUAL PAGES. AFTER REPAIR PROCEDURE INSPECTION RESULTS Yes No Go to next step.DRFT. replace pressure regulator. 3 4 Yes No Yes No 5 Install vacuum gauge to intake manifold. Is fuel line pressure correct at idle? Fuel line pressure 210—250kPa {2. Access ECT P1D. Retrieve any DTC. MANUAL TO. Inspect for fuel leakage inside pressure regulator. causing serious injury and damage. MODEL . FROM. Inspect ignition timing.INDEX RANG. Inspect for cause. If it does not change. Verify that fuel pressure gauge reading changes as vacuum changes.CHAPTER. DTC is displayed: Go to appropriate DTC test. inspect vacuum line.g. Go to next step.INDEX TROUBLESHOOTING SYMPTOM 12 DESCRIPTION KNOCKING/PINGING . If okay. Measure fuel line pressure at idle. Verify ECT PID is less than 116°C {241 °F} while driving.ACCELERATION/CRUISE • • • • Sound is produced when air/fuel mixture is ignited by something other than spark plug (e. Start engine and run it at idle. Start engine. Connect vacuum hose to pressure regulator. Engine overheating due to cooling system malfunction Inadequate engine compression Inadequate fuel pressure POSSIBLE CAUSE Warning Following troubleshooting flowchart contains fuel system diagnosis and repair procedures. • Fuel line spills and leaks are dangerous. Read following warnings before performing fuel system service: • Fuel vapor is hazardous. Fuel can also irritate skin and eyes. hot spot in combustion chamber). Inspect for open fuel pump relief valve. Go to next step. If it changes. Always keep sparks and flames away from fuel. Inspect cooling system for cause of overheating.

REPAIR MANUAL PAGES. Connect NGS tester to DLC. Zero or low: Inspect fuel pump circuit. Inspect the following: • High-tension leads • Ignition coil and connector Go to next step. Go to next step.6 kgf/cm 2. Fuel can ignite and cause serious injuries or death and damage. or thermostat operation. go to next step. • Fuel quality • Coolant level Are all items okay? Repeat Step 1. Read following warnings before performing fuel system service: • Fuel vapor is hazardous. MANUAL TO. Is fuel line pressure correct at idle? Fuel line pressure 210—250kPa {2.DRFT. Measure fuel line pressure at idle. Yes No DTC is displayed: 2 Turn ignition switch on. Contaminated air cleaner element Engine cooling system malfunction Improper automatic transmission fluid level Weak spark Poor fuel quality Improper coolant level Inadequate fuel pressure Spark plug malfunction PCV valve malfunction Brake dragging Improper valve timing due to jumping out of timing belt Contaminated MAF sensor Improper engine compression Exhaust system clogging POSSIBLE CAUSE Warning Following troubleshooting flowchart contains fuel system diagnosis and repair procedures. It can easily ignite.INDEX RANG. Inspect for open fuel pump relief valve. always complete "BEFORE REPAIR PROCEDURE" and "AFTER REPAIR PROCEDURE" described in this manual.1—2. To prevent this. Inspect for fuel leakage inside pressure regulator. Inspect following: • Air cleaner element for contamination • Automatic transmission fluid level No Service as necessary. If okay. 30—36 psi} Yes No CONTINUED F1-98 . Drive vehicle while monitoring PID. ☞ FUEL SYSTEM. Access ECT PID.CHAPTER. • Fuel line spills and leaks are dangerous.TO. PASSED" display? 3 Connect NGS tester to DLC. MODEL . Inspect for clogged fuel return line.INDEX TROUBLESHOOTING SYMPTOM 13 DESCRIPTION POOR FUEL ECONOMY • • • • • • • • • • • • • • • Fuel economy is unsatisfactory.BACK. PCM INSPECTION Is PID within specification? Is strong blue spark visible at each disconnected high-tension lead while cranking engine? Yes No Go to next step. Inspect for coolant leakage. Fuel can also irritate skin and eyes. AFTER REPAIR PROCEDURE STEP INSPECTION RESULTS ACTION 1 Yes Go to next step. ☞ CONTROL SYSTEM. Always keep sparks and flames away from fuel. FROM. Inspect for clogged main fuel line. BEFORE REPAIR PROCEDURE ☞ FUEL SYSTEM. No DTC is displayed: Is "NO CODES RECEIVED" or "SYSTEM Go to appropriate DTC test. Start engine and run it at idle. 4 Yes No 5 Install fuel pressure gauge between fuel main pipe and fuel distributor. cooling fan operation. causing serious injury and damage. Retrieve any DTCs. High: Inspect pressure regulator for high pressure cause. Inspect for following: • Spark plug malfunction Repair or replace malfunctioning parts.

INDEX TROUBLESHOOTING STEP INSPECTION 6 Remove and shake PCV valve. Go to next step. FROM. Does PCV valve rattle? 7 8 9 10 11 Is there restriction in exhaust system? Is brake system functioning properly? Inspect for contaminated MAF sensor.BACK. Replace MAP sensor. CONTINUED F1-99 . Inspect for cause. MODEL .CHAPTER.INDEX RANG. MANUAL TO. Inspect for cause. ACTION Verify test results. Inspect valve timing. No Yes No Yes No Yes No Yes No Replace PCV valve.DRFT. If okay. return to diagnostic index to service any additional symptoms. Go to next step.TO. Inspect exhaust system. Go to next step. Is there any contamination? Is engine compression correct? RESULTS Yes Go to next step.REPAIR MANUAL PAGES.

Inspect for fuel leakage inside pressure regulator.CHAPTER. Inspect for open fuel pump relief valve. DTC is displayed: Go to appropriate DTC test. MODEL . Inspect following: • High-tension leads • Ignition coil and connector Go to next step.REPAIR MANUAL PAGES. 3 4 5 No 6 Install fuel pressure gauge between fuel main pipe and fuel distributor. Is "NO CODES RECEIVED" or "SYSTEM PASSED" displayed? Is any other drivability concern present? Connect NGS tester to DLC. Inspect for coolant leakage. causing serious injury and damage. If okay. Go to appropriate symptom troubleshooting. Retrieve any DTC. MANUAL TO. Is fuel line pressure correct at idle? Fuel line pressure 210—250 kPa { 2. Measure fuel line pressure at idle. Inspect for following: • Spark plug malfunction Repair or replace malfunctioning parts.INDEX RANG.INDEX TROUBLESHOOTING SYMPTOM 14 DESCRIPTION EMISSION COMPLIANCE • Emission compliance test is failed.1—2. 2 Yes No Yes No Yes No Yes No DTC is displayed: Go to next step. 30—36 psi} Yes No CONTINUED F1-100 .BACK. ☞ FUEL SYSTEM. AFTER REPAIR PROCEDURE STEP 1 INSPECTION Inspect following: • Vacuum lines for leakage or blockage • Electrical connections • Proper maintenance schedule followed • Intake-air system and air cleaner element concerns: obstructions. Inspect for clogged fuel return line. FROM. Go to next step. Go to next step. Zero or low: Inspect fuel pump circuit. Access ECT PID. always complete "BEFORE REPAIR PROCEDURE" and "AFTER REPAIR PROCEDURE" described in this manual. leakage or dirt Are all items okay? Connect NGS tester to DLC. go to next step. • Fuel line spills and leaks are dangerous. Is ECT PID correct? Is strong blue spark visible at each disconnected high-tension lead while cranking engine? RESULTS Yes Go to next step. ACTION No Service as necessary. cooling fan operation or thermostat operation. • • • • • • • • • • • Vacuum line leakage or blockage Cooling system malfunction Spark plug malfunction Leakage from intake manifold Inadequate fuel pressure PCV valve malfunction or incorrect valve installation Exhaust system clogging Fuel tank ventilation system malfunction Charcoal canister damage Excessive carbon built up in combustion chamber Improper engine compression Improper valve timing POSSIBLE CAUSE Warning Following troubleshooting flowchart contains fuel system diagnosis and repair procedures. To prevent this. Always keep sparks and flames away from fuel. It can easily ignite. High: Inspect pressure regulator for high pressure cause. Repeat Step 1. Start engine and run it at idle. Turn ignition switch on.6 kgf/cm2. Warm up engine and run it at idle.DRFT. Read following warnings before performing fuel system service: • Fuel vapor is hazardous.TO. BEFORE REPAIR PROCEDURE ☞ FUEL SYSTEM. Inspect for clogged main fuel line. Fuel can also irritate skin and eyes. Fuel can ignite and cause serious injuries or death and damage.

HIGH OIL CONSUMPTION/LEAKAGE • Oil consumption is excessive.TO.6 kgf/cm 2. No Yes Replace PCV valve. valve stem seals. 30—36 psi} Remove and shake PCV valve. If okay. return to diagnostic index to service any additional symptoms. If okay.INDEX RANG. return to diagnostic index to service any additional symptoms. ACTION No Inspect pressure regulator for high pressure cause. MANUAL TO.INDEX TROUBLESHOOTING STEP 7 INSPECTION Does fuel line pressure remain at specification for 60 seconds when ignition switch is turned on? Fuel line pressure 210—250kPa {2. 8 9 10 Yes No Yes No Yes No Go to next step. FROM. Inspect fuel tank vent system.BACK. cylinder head drain passage. MODEL . Service as necessary. Does PCV valve rattle? 2 Inspect for following: • External leakage • Proper dipstick • Proper engine oil viscosity Are all items okay? No 3 Verify test results.DRFT.1—2. Inspect exhaust system. Inspect internal engine parts such as valves. ACTION SYMPTOM 15 DESCRIPTION POSSIBLE CAUSE STEP INSPECTION 1 Remove and shake PCV valve. • PCV valve malfunction • Improper dipstick • Improper engine oil viscosity • Engine internal parts malfunction RESULTS Yes Go to next step. Does PCV valve rattle? Is there restriction in the exhaust system? Inspect for fuel saturation inside charcoal canister. Repeat Step 2. Go to next step. piston rings. Replace charcoal canister.REPAIR MANUAL PAGES. CONTINUED F1-101 . 11 Verify test results. Replace PCV valve. valve guides. Is excessive amount of liquid fuel present in canister? RESULTS Yes Go to next step.CHAPTER.

Inspect for following and repair or replace as necessary: • Refrigerant charging amount • Open circuit between A/C relay and PCM terminal 1J • Seized A/C magnetic clutch • A/C magnetic clutch malfunction If all Items are okay. Go to next step. 3 4 Connect NGS tester to DLC. 2 Yes No Yes No No DTC is displayed: Go to next step. FROM. Access A/C SW PID on NGS tester. Inspect and service heater for leakage. MODEL . Inspect for following: • Refrigerant pressure switch operation • A/C switch stuck open • Open or short circuit between refrigerant pressure switch and PCM terminal 1Q • Open circuit of blower motor fan switch and resistor (if blower motor does not operate) • Evaporator temperature sensor and A/C amplifier Go to next step. Go to next step.INDEX TROUBLESHOOTING SYMPTOM 16 DESCRIPTION COOLING SYSTEM CONCERNS . Go to Step 5. Turn A/C switch on.INDEX RANG. MANUAL TO. Does A/C SW PID read ON? Yes No 5 6 7 Is drive belt okay? Is there any leakage around heater unit in passenger compartment? Is there any leakage at coolant hoses and/or radiator? Yes No Yes No Yes No CONTINUED F1-102 . go to next step. Start engine and run it at idle speed. Does A/C compressor engage? No Service as necessary. Improper coolant level Blown fuses Coolant leakage/Improper coolant level Excessive A/C system pressure Improper water/anti-freeze mixture Fans reverse rotation Poor radiator condition Thermostat malfunction Radiator hose damage Improper or damaged radiator cap Main cooling fan is inoperative. Turn ignition switch on. POSSIBLE CAUSE STEP 1 ACTION Inspect following: • Engine coolant level • Coolant leakage • Water and anti-freeze mixture • Radiator condition • Collapsed or restricted radiator hoses • Radiator pressure cap • Overflow system • Fan rotational direction • Fuses Are all items okay? Connect NGS tester to DLC.CHAPTER. Is "NO CODES RECEIVED" or "SYSTEM PASSED" displayed? Start engine and run it at idle speed. Repeat Step 1.OVERHEATING • • • • • • • • • • • • • • Engine runs at higher than normal temperature/overheats. Retrieve any DTC. Turn A/C switch on. Replace malfunctioning parts.REPAIR MANUAL PAGES. Coolant overflow system malfunction Improper tension of drive belt Drive belt damage INSPECTION RESULTS Yes Go to next step.TO.DRFT. DTC is displayed: Go to appropriate DTC test. Replace drive belt.BACK. Go to next step.

inspect temperature gauge and heat gauge unit. inspect ECT sensor. ☞ Section E. Access ECT V PID on NGS tester. If temperature gauge on instrument cluster indicates normal range but ECT V PID is not same as temperature gauge reading. If okay. Go to symptom troubleshooting No. CONTINUED F1-103 . THERMOSTAT.REPAIR MANUAL PAGES. MODEL . THERMOSTAT INSPECTION Is thermostat okay? RESULTS Yes No ACTION Engine coolant temperature and thermostat are okay.8 "Fast idle/runs on". return to diagnostic index to service any additional symptoms. If temperature gauge on instrument cluster indicates overheating but ECT V is normal. MANUAL TO. ☞ Section E. Replace thermostat. Go to next step. FROM. If temperature gauge on instrument cluster indicates normal range but ECT V is not same as temperature gauge reading. If temperature gauge on instrument cluster indicates cold range but ECT voltage is normal. Inspect for both ECT V and temperature gauge readings.INDEX TROUBLESHOOTING STEP 8 INSPECTION Cool down engine. Inspect for both ECT V PID and temperature gauge on instrument cluster readings. Is customer complaint "Lack of passenger compartment heat" only? Does engine speed continue at fast idle? Remove thermostat and inspect operation. If okay. THERMOSTAT. Access ECT V PID on NGS tester.DRFT. Remove thermostat and inspect operation.INDEX RANG.BACK. inspect temperature gauge and heat gauge unit. inspect ECT sensor. Thermostat malfunction Cooling fan system malfunction INSPECTION RESULTS Yes No Yes No Yes Go to next step. COOLING SYSTEM CONCERNS .CHAPTER. 9 Verify test results.TO. inspect engine block for leakage or blockage.RUNS COLD • • • Engine takes excessive period for reaching normal operating temperature. SYMPTOM 17 DESCRIPTION POSSIBLE CAUSE STEP 1 2 3 ACTION Inspect A/C and heater system. return to diagnostic index to service any additional symptoms. THERMOSTAT INSPECTION Is thermostat okay? No 4 Verify test results.

TO.DRFT. Replace PCV valve. Fuel can also irritate skin and eyes. Inspect for following: • Cylinder head gasket leakage • Intake manifold gasket leakage • Cracked or porous engine block If other drivability symptoms are present. • Fuel line spills and leaks are dangerous. MODEL . Blue smoke (Burning oil): • PCV valve malfunction • Engine internal oil leakage White smoke (Water in combustion): • Cooling system (coolant loss) malfunction • Engine internal coolant leakage Black smoke (Rich fuel mixture): • Air cleaner restriction • Intake-air system is collapsed or restricted.INDEX TROUBLESHOOTING SYMPTOM 18 DESCRIPTION EXHAUST SMOKE • Blue. Fuel can ignite and cause serious injuries or death and damage. Turn ignition switch on. Does PCV valve rattle? Yes ACTION Burning oil is indicated. black. • Excessive fuel pressure • Improper engine compression • Injector fuel leakage • Ignition system malfunction Warning Following troubleshooting flowchart contains fuel system diagnosis and repair procedures. or white smoke from exhaust system. • Fuel return line is restricted. ☞ FUEL SYSTEM. Inspect for cause. Inspect for following: • Damaged valve guide. stems or valve seals • Blocked oil drain passage in cylinder head • Piston rings are not seated. POSSIBLE CAUSE No 3 Does cooling system hold pressure? Yes No 4 Inspect for following: • Air cleaner restriction • Collapsed or restricted intake-air system • Restricted fuel return line Are all items okay? Connect NGS tester to DLC. Service as necessary.INDEX RANG. return to diagnostic index to service any additional symptoms. Is "NO CODES RECEIVED" or "SYSTEM PASSED" displayed? Yes No 5 Yes No F1-104 CONTINUED . always complete "BEFORE REPAIR PROCEDURE" and "AFTER REPAIR PROCEDURE" described in this manual. It can easily ignite. Go to next step. return to diagnostic index to service any additional symptoms.REPAIR MANUAL PAGES.CHAPTER. seized or worn • Damaged cylinder bore If other drivability symptoms are present. FROM. BEFORE REPAIR PROCEDURE ☞ FUEL SYSTEM. No DTC Is displayed: Go to next step. Water in combustion is indicated. Go to Step 4. AFTER REPAIR PROCEDURE STEP 1 INSPECTION What color is smoke coming from exhaust system? RESULTS Blue White Black 2 Remove and shake PCV valve. causing serious injury and damage. To prevent this. Repeat Step 4. Rich fuel mixture is indicated. DTC is displayed: Go to appropriate DTC test. Go to Step 3. MANUAL TO.BACK. Retrieve any DTC. Read following warnings before performing fuel system service: • Fuel vapor is hazardous. Go to next step. Always keep sparks and flames away from fuel.

CHAPTER. Start engine and run it at idle. Inspect following: • High-tension leads • Ignition coil and connector 9 Verify test results.INDEX RANG.REPAIR MANUAL PAGES. return to diagnostic index to service any additional symptoms. MANUAL TO. If okay.6 kgf/cm 2.30—36 psi} Is strong blue spark visible at each disconnected high-tension lead while cranking engine? RESULTS Yes Go to next step. Yes No Inspect pressure regulator for high pressure cause.1—2. MODEL . Measure fuel line pressure at idle.DRFT. Is fuel line pressure correct at idle? Fuel line pressure 210—250 kPa {2.INDEX TROUBLESHOOTING STEP INSPECTION 6 Install fuel pressure gauge between fuel main pipe and fuel distributor. CONTINUED F1-105 . No ACTION Zero or low: Inspect fuel pump circuit Inspect for open fuel pump relief valve Inspect for fuel leakage inside pressure regulator Inspect for clogged main fuel line High: Inspect pressure regulator for high pressure cause Inspect for clogged fuel return line Go to next step. FROM.TO.1—2.BACK.6 kgf/cm 2. 8 Yes No Inspect spark plugs.30—36 psi} 7 Does fuel line pressure remain at specification for 60 seconds when ignition switch is turned on? Fuel line pressure 210—250kPa {2.

always complete "BEFORE REPAIR PROCEDURE" and "AFTER REPAIR PROCEDURE" described in this manual. Service as necessary. AFTER REPAIR PROCEDURE INSPECTION RESULTS Yes Go to next step. ☞ EMISSION SYSTEM.REPAIR MANUAL PAGES. Does fuel line pressure remain at specification for 60 seconds when ignition switch is turned on and off? Fuel line pressure 210—250 kPa {2.BACK.INDEX TROUBLESHOOTING SYMPTOM 19 DESCRIPTION FUEL ODOR (IN ENGINE COMPARTMENT) • • • • Gasoline fuel smell or visible leakage. PURGE SOLENOID VALVE INSPECTION Is solenoid operating properly? Connect NGS tester to DLC. 30—36 psi} Inspect for blockage/restriction or open between engine vacuum port and charcoal canister. Is fault indicated? Inspect purge solenoid valve. Replace purge solenoid valve. • Fuel line spills and leaks are dangerous. Inspect for blockage in fuel tank vent system.INDEX RANG. return to diagnostic index to service any additional symptoms. No Go to next step.6 kgf/cm 2. replace charcoal canister. MODEL . Verify test results.CHAPTER. Always keep sparks and flames away from fuel. 3 Yes No Yes Go to next step. Read following warnings before performing fuel system service: • Fuel vapor is hazardous. CONTINUED F1-106 . Excessive fuel pressure Fuel tank vent system blockage Charcoal canister malfunction POSSIBLE CAUSE Warning Following troubleshooting flowchart contains fuel system diagnosis and repair procedures. Retrieve any DTC.TO. If excessive amount of liquid fuel is present. Turn ignition switch on. causing serious injury and damage. It can easily ignite. 2 Yes Replace vacuum hose.1—2. FROM. No DTC is displayed: Go to appropriate DTC test. Start engine and run it at idle. 4 5 No DTC is displayed: Inspect charcoal canister for fuel saturation. ☞ FUEL SYSTEM. Is "NO CODES RECEIVED" or "SYSTEM PASSED" displayed? No Inspect pressure regulator for high pressure cause. BEFORE REPAIR PROCEDURE ☞ FUEL SYSTEM.DRFT. Install fuel pressure gauge between fuel main pipe and fuel distributor. Then stop engine. Fuel can also irritate skin and eyes. ACTION STEP 1 Visually inspect for fuel leakage at fuel injector O-ring and fuel line. To prevent this. Fuel can ignite and cause serious injuries or death and damage. MANUAL TO. If okay.

Inspect exhaust system for loose parts. No CONTINUED F1-107 . Go to symptom troubleshooting No. FROM. POSSIBLE CAUSE STEP INSPECTION 1 Is squealing. clicking or chirping noise: • Improper engine oil level • Improper drive belt tension Rattling noise: • Loose parts Hissing sound noise: • Vacuum leakage • Loose spark plug • Air leakage from intake-air system Rumbling or grinding noise: • Improper drive belt tension Rapping or roar noise: • Exhaust system looseness Other noise: • Camshaft friction gear noise RESULTS ACTION Yes Inspect engine oil level or drive belts. Service as necessary for other parts. Inspect drive belt.BACK. clicking or chirping sound present? 2 Is rumbling or grinding sound present? No 5 6 Is rapping or roaring sound present? Is knocking sound present? Yes No Yes No 7 If noise comes from inside engine. Go to next step. return to diagnostic index to service any additional symptoms. VIBRATION CONCERNS (ENGINE) • Vibration from under hood or driveline • Loose attaching bolts or worn parts • Component malfunctions such as worn parts INSPECTION Inspect following components for loose attaching bolts or worn parts: • Cooling fan • Drive belt and pulleys • Engine mounts Are all items okay? RESULTS Yes ACTION Inspect following systems: • Wheels • Driveline • Suspension SYMPTOM 21 DESCRIPTION POSSIBLECAU SE STEP 1 2 Readjust or retighten engine mount installation position.12 "Knocking/ pinging".REPAIR MANUAL PAGES.CHAPTER. No Yes No 3 4 Is rattling sound present? Is hissing sound present? Yes No Yes Go to next step. return to diagnostic index to service any additional symptoms. If okay. MANUAL TO. MODEL .TO. If okay. Verify test results. Go to next step. Inspect following: • Vacuum leakage • Spark plug looseness • Intake-air system leakage Go to next step. Go to next step. Verify test results.INDEX TROUBLESHOOTING SYMPTOM 20 DESCRIPTION ENGINE NOISE • Engine noise from under hood Squealing. inspect for friction gear noise.INDEX RANG.DRFT. Inspect location of rattle for loose parts.

INDEX TROUBLESHOOTING SYMPTOM 22 DESCRIPTION A/C DOES NOT WORK SUFFICIENTLY.CHAPTER. Retrieve any DTC.REPAIR MANUAL PAGES. Start engine. Start engine and turn A/C switch on.INDEX RANG. Access A/C SW PID on NGS tester. A/C relay is stuck open. If okay. If GND condition is okay. Is "NO CODES RECEIVED" or "SYSTEM PASSED" displayed? Disconnect A/C compressor connector. • Open circuit between refrigerant pressure switch and PCM terminal 1Q • Open circuit of blower motor fan switch and resistor (if blower motor does not operate) • Evaporator temperature sensor and A/C amplifier • Open circuit between A/C amplifier and refrigerant pressure switch ACTION POSSIBLE CAUSE STEP 1 2 No Yes 3 No Yes 4 No 5 Verify test results.5V Connect NGS tester to DLC. Inspect for stuck open A/C relay. Inspect for GND condition of magnetic clutch on A/C compressor. Turn ignition switch on. Go to next step. return to diagnostic index to service any additional symptoms. Inspect for following: • Refrigerant charging amount • Refrigerant pressure switch operation Inspect for following: • A/C switch is stuck open. CONTINUED F1-108 . Go to next step. MODEL . Is there correct voltage at terminal of A/C compressor magnetic clutch connector? Specification More than 10. Turn A/C switch on and set blower fan at any speed. MANUAL TO.TO. inspect for open circuit of magnetic clutch coil. FROM. Does A/C SW PI Dread ON? Disconnect refrigerant pressure switch connector. Replace as necessary. Connect a jumper wire between terminals of refrigerant pressure switch connector.DRFT. • • • • • • • • • A/C compressor magnetic clutch does not engage when A/C switch is turned on. DTC is displayed: Go to appropriate DTC test.BACK. Seized A/C compressor Open circuit between A/C switch and PCM through both refrigerant pressure switch and A/C amplifier INSPECTION Connect NGS tester to DLC. Does A/C work? RESULTS Yes No Yes No DTC is displayed: Go to next step. Start engine and turn A/C switch on. Improper refrigerant charging amount Open A/C magnetic clutch Open circuit between A/C relay and A/C magnetic clutch Poor GND of A/C magnetic clutch Refrigerant pressure switch is struck open.

CONTINUED F1-109 . Does A/C SW PID reading remain ON? Yes No Go to next step. Remove A/C relay. short to GND circuit may be present. Stuck engagement A/C relay is stuck closed. Is "NO CODES RECEIVED" or "SYSTEM PASSED" displayed? Start engine and run it at idle. Inspect for short to GND circuit between refrigerant pressure switch and PCM terminal 10. short to GND circuit may be No Inspect for stuck closed A/C switch. MODEL . Start the engine and turn A/C switch on.CHAPTER. Note • A/C SW PID should read OFF when disconnecting connector. go to next step. Retrieve any DTC.BACK. If okay. DTC is displayed: Go to appropriate DTC test. • • • • • • A/C compressor magnetic clutch does not disengage. MANUAL TO. ACTION POSSIBLE CAUSE STEP 1 2 No 3 Connect NGS tester to DLC. return to diagnostic index to service any additional symptoms. amplifier Note • Short to GND circuit between A/C amplifier and • A/C SW PID should read OFF when turnrefrigerant pressure switch ing A/C switch off.REPAIR MANUAL PAGES. If A/C SW PID reading remains ON. Access A/C SW PID on NGS tester.DRFT. • Short to GND circuit between A/C switch and A/C Read A/C SW PID while turning off A/C switch.INDEX TROUBLESHOOTING SYMPTOM 23 DESCRIPTION A/C IS ALWAYS ON /A/C COMPRESSOR RUNS CONTINUOUSLY. Does A/C magnetic clutch disengage? RESULTS Yes No Yes No DTC is displayed: Go to next step. Does A/C SW PID reading remain ON? Verify test results. inspect magnetic clutch engagement or clearance. • Short to GND circuit between A/C relay and PCM terminal 1J If both items okay. present.INDEX RANG. Inspect if circuit between A/C relay and magnetic clutch shorts to battery power circuit. If circuit is okay. If A/C SW PID reading remains ON. Turn A/C switch on. Short to GND between A/C switch and PCM Short to GND circuit between A/C relay and PCM A/C relay to magnetic clutch circuit shorts to battery power INSPECTION Connect NGS tester to DLC.TO. FROM. Inspect for following: • A/C relay is stuck closed. Turn ignition switch on. Read A/C SW PID while disconnecting refrigerant pressure switch connector. 4 5 Reconnect refrigerant pressure switch Yes Inspect for following: connector.

TO. No Yes No ACTION STEP INSPECTION 1 Does A/C compressor disengage when A/C switch is turned off? 2 Connect NGS tester to DLC. RESULTS Yes Go to next step.BACK. 3 Verify test results.DRFT.REPAIR MANUAL PAGES.INDEX TROUBLESHOOTING SYMPTOM 24 DESCRIPTION POSSIBLE CAUSE A/C DOES NOT CUT OFF UNDER WIDE OPEN THROTTLE (WOT) CONDITIONS • A/C compressor magnetic clutch does not disengage under WOT. No DTC is displayed: Inspect TP sensor for proper adjustment.INDEX RANG. DTC is displayed: Go to appropriate DTC test.23 "A/C is always on / A/C compressor runs continuously".CHAPTER. CONTINUED F1-110 . Is "NO CODES RECEIVED" or "SYSTEM PASSED" displayed? Go to symptom troubleshooting No. Turn ignition switch on. MANUAL TO. MODEL . If okay. return to diagnostic index to service any additional symptoms. Retrieve any DTC. • TP sensor malfunction • TP sensor misadjustment • TP sensor is loosely installed. FROM.

No DTC is displayed: Go to next step.BACK. Read following warnings before performing fuel system service: • Fuel vapor is hazardous. Turn ignition switch on. always complete "BEFORE REPAIR PROCEDURE" and "AFTER REPAIR PROCEDURE" described in this manual. ☞ FUEL SYSTEM. BEFORE REPAIR PROCEDURE ☞ FUEL SYSTEM. Retrieve any DTC. Inspect for fuel leakage inside pressure regulator. Fuel can ignite and cause serious injuries or death and damage. Go to next step.INDEX TROUBLESHOOTING SYMPTOM 25 EXHAUST SULPHUR SMELL • • • • Rotten egg smell (sulphur) from exhaust Electrical connectors are disconnected or connected poorly Charcoal canister malfunction Vacuum lines are disconnected or connected improperly. 30—36 psi} Inspect charcoal canister for fuel saturation. 7 Inspect fuel tank vent system.DRFT. Yes No Replace charcoal canister. STEP 1 2 Are any drivability or exhaust smoke concerns present? Inspect following: • Electrical connections • Vacuum lines Are all items okay? Connect NGS tester to DLC. since sulfur content can vary in different fuels. • Fuel line spills and leaks are dangerous.1—2. Go to next step. Inspect for clogged fuel return line.TO. Zero or low: Inspect fuel pump circuit.REPAIR MANUAL PAGES.6 kgf/cm 2. Is "NO CODES RECEIVED" or "SYSTEM PASSED" displayed? Install fuel pressure gauge between fuel filter and fuel distributor. If fuel tank vent system is okay. Inspect for clogged main fuel line. Start engine and run it at idle.INDEX RANG. Is excessive amount of liquid fuel present in canister? Yes No Inspect pressure regulator for high pressure cause. Verify test results.CHAPTER. Go to next step. To prevent this. FROM. High: Inspect pressure regulator for high pressure cause. suggest trying a different brand. DTC is displayed: Go to appropriate DTC test.6 kgf/cm 2.1—2.30—36 psi} 3 4 5 6 Does fuel line pressure remain at specification for 60 seconds when ignition switch is turned on? Fuel line pressure 210—250kPa {2. Inspect for open fuel pump relief valve. If fuel tank vent system is not okay. Fuel can also irritate skin and eyes. It can easily ignite. causing serious injury and damage. Service as necessary. Always keep sparks and flames away from fuel. Is fuel line pressure correct at idle? Fuel line pressure 210—250kPa {2. AFTER REPAIR PROCEDURE INSPECTION RESULTS Yes No Yes No Yes No Yes No Go to next step. CONTINUED F1-111 . Improper fuel pressure DESCRIPTION • POSSIBLE CAUSE Warning Following troubleshooting flowchart contains fuel system diagnosis and repair procedures. MANUAL TO. repair or replace malfunctioning parts. return to diagnostic index to service any additional symptoms. ACTION Go to appropriate flow chart. MODEL . Repeat Step 2. If okay.

Are any PID values out of range. wiggle and pull each wire/connector at suspect component or PCM. Fault occurred while spraying wiring: Inspect each wire for corrosion. Lightly tap on suspect component. Are any PID values out of range. Go to Symptom Index. Inspect wire and connector at suspect component for corrosion.TO. or do they suddenly change and go back into range? Start engine. DESCRIPTION • STEP 1 INSPECTION Talk to customer.BACK. Are any PID values out of range.INDEX TROUBLESHOOTING SYMPTOM 26 INTERMITTENT CONCERNS Symptom occurs randomly and is difficult to diagnose. 3 Yes Inspect each wire for corrosion. or do they suddenly change and go back into range? Start engine.DRFT. Turn ignition switch on. poor wire terminal crimps and high tension of wire. or do they suddenly change and go back into range. wiggle and pull each wire/connector at suspect component or PCM. FROM. Repair as necessary.CHAPTER. bent or loose terminal crimps. Access PIDs for suspect component.REPAIR MANUAL PAGES. bent or loose terminals. or was there a noticeable engine misfire/ stumble? RESULTS Yes No Yes Go to next step. MANUAL TO. bent or loose terminals and poor wire terminal crimps. Fault occurred while spraying component: Replace part and verify repair. MODEL . Fault occurred while spraying vacuum line: Repair vacuum hoses. Inspect each wire for corrosion. If input is switch-type component. No Yes 4 No CONTINUED F1-112 . Retrieve vehicle service history. Lightly tap on suspect component. component or vacuum line related to possible fault area. bent or loose terminal crimps. Go to next step. turn on manually. ACTION 2 No Go to next step. Accurately spray water on suspect component wire. Does vehicle have a number of previous repairs and components replaced for a certain symptom? Connect NGS tester to DLC.INDEX RANG.

Turn ignition switch on. No Go to Step 10. Leave TP sensor and variable resistor (Except Europe) connector disconnected. variable resistor (Except Europe) and PCM connectors disconnected. Can ECT PID be accessed? Turn ignition switch off. Reconnect TP sensor and variable resistor (Except Europe) connector.0 ohms? Note • The purpose of this step is to determine if NGS tester is communicating with PCM. replace PCM. Is resistance less than 5. Turn ignition switch on. Disconnect PCM connector. 6 Yes Inspect for constant voltage at TP sensor and variable resistor (Except Europe) connector again. 2 3 Yes No Yes Go to next step. Leave TP sensor and variable resistor (Except Europe) connector disconnected.INDEX RANG. FROM.5 volts? Turn ignition switch off.5 volts? Leave TP sensor. Is resistance greater than 10.0 volts? Is voltage across battery terminals greater than 10. Measure voltage between PCM connector terminals 1B and 2B.000 ohms? Turn ignition switch off. Disconnect NGS tester from DLC.5 volts and within 1.DRFT. Turn ignition switch on. No Go to next step. Measure resistance between PCM connector terminal 2K and constant voltage circuit at appropriate sensor connector. 8 Yes Go to next step. MODEL . Is voltage greater than 10. INSPECTION Disconnect TP sensor connector.INDEX TROUBLESHOOTING SYMPTOM 27 CONSTANT VOLTAGE DESCRIPTION Incorrect constant voltage POSSIBLE CAUSE STEP 1 • Constant voltage circuit malfunction Note • TP sensor and variable resistor (Except Europe) use constant voltage. No Repair open circuit between PCM terminal 1B and main relay. If constant voltage is still out of range. Measure voltage between following TP sensor and variable resistor (Except Europe) connector terminals: • Constant voltage terminal .GND terminal Is constant voltage greater than 6. Leave TP sensor and variable resistor (Except Europe) connector disconnected. No Go to next step. Attempt to access ECT PID.TO. Go to next step. Measure voltage between battery positive terminal and GND circuit at TP sensor connector. 5 Yes Go to next step.CHAPTER. Measure resistance between PCM connector terminals 2K and 2B. If constant voltage is still out of range.0 volt of battery voltage? Note • The purpose of this step is to determine if NGS tester is communicating with PCM. Inspect for constant voltage at TP sensor and variable resistor (Except Europe) connector again. Can ECT PID be accessed? RESULTS Yes ACTION Repair constant voltage circuit short to power in harness. Disconnect PCM connector. No Go to Step 8. CONTINUED F1-113 . Is voltage greater than 10. Inspect charging system. Repair constant voltage circuit short to GND. Turn ignition switch on. Attempt to access ECT PID. No Yes 7 No Repair open constant voltage circuit. 4 Yes Go to Step 7. replace PCM. MANUAL TO.REPAIR MANUAL PAGES.BACK.

2B and 2C. Go to appropriate DTC test. Disconnect PCM connector. No Yes Repair open GND circuit. Measure resistance between GND circuit at following sensor connector and GND: • ECT sensor • O2S • IAT sensor • MAF sensor • TP sensor • Variable resistor (Except Europe) Is each resistance less than 5. Disconnect NGS tester from DLC.TO. CONTINUED F1-114 .0 ohms? RESULTS Yes ACTION Reconnect sensor connector. GND circuits are okay. Disconnect PCM connector.REPAIR MANUAL PAGES. FROM. 10 Yes Go to next step.BACK.DRFT. No Repair open GND circuit. Measure resistance between battery negative terminal and PCM terminals 2A. MODEL . Is resistance less than 5.0 ohms? Turn ignition switch off.INDEX RANG. Is each resistance less than 5.INDEX TROUBLESHOOTING STEP 9 INSPECTION Turn ignition switch off. Inspect for constant voltage at TP sensor and variable resistor (Except Europe) connector again.0 ohms? Turn ignition switch off. Measure resistance between GND circuit at appropriate sensor connector and PCM connector terminal 2D. 11 No Inspect for open GND circuit.CHAPTER. MANUAL TO.

Go to next step. FROM. Troubleshooting chart Wet/carbon stuck on specific plug Grayish white with specific plug Wet/carbon stuck on all plugs Grayish white with all plugs Symptom 1 Symptom 2 Symptom 3 Symptom 4 POSSIBLE CAUSE Warning Following troubleshooting flowchart contains fuel system diagnosis and repair procedures.7—3. Fuel Line Pressure Inspection Is fuel line pressure correct? Fuel line pressure 270—310 kPa {2. No Yes Go to next step.2 kgf/cm 2. Inspect for clogged fuel return line. COMPRESSION INSPECTION Is compression pressure correct? Install all spark plugs.INDEX RANG. Go to next step. ☞ Section B1. Spark plug condition Specific plug is wet or covered with carbon. 3. STEP INSPECTION 1 Is spark plug wet/covered with carbon by engine oil? 2 Inspect spark plug for following: • Cracked insulator • Heating value • Air gap • Worn electrode Is spark plug okay? Inspect compression pressure at suspected faulty cylinder. 4 5 No F1-115 CONTINUED . 3 Yes No Yes No Yes Go to next step. Always keep sparks and flames away from fuel. To prevent this. ENGINE SYSTEM INSPECTION. All plugs look grayish white.INDEX TROUBLESHOOTING DIAGNOSTIC INSPECTION Spark Plug Condition Inspection Purpose Inspecting spark plugs condition can determine whether problem is related to a specific cylinder or to all cylinders.BACK. AFTER REPAIR PROCEDURE RESULTS ACTION Yes Working up and down inspect all areas related to oil. It can easily ignite. Inspect for fuel leakage inside pressure regulator. causing serious injury and damage. Repair or replace malfunctioning parts. BEFORE REPAIR PROCEDURE ☞ FUEL SYSTEM. Read following warnings before performing fuel system service: • Fuel vapor is hazardous.CHAPTER. Go to appropriate troubleshooting chart for further information. All plugs are wet or covered with carbon. Inspect for fuel pump relief valve open. ☞ FUEL SYSTEM. SYMPTOM 1 Wet/carbon stuck on specific plug • • • • Spark—No spark visible or spark weak Air/fuel mixture—Excessive fuel injection volume Compression—No compression.REPAIR MANUAL PAGES. Repair or replace malfunctioning parts. MANUAL TO. Specific plug looks grayish white. Inspect fuel injector for following: • Open or short in injector • Leakage • Injection volume Zero or low: Inspect fuel pump circuit. Fuel can also irritate skin and eyes. Inspect spark plug condition. MODEL . Inspect for clogged main fuel line. Carry out spark test at suspected faulty cylinder. 39—45 psi} No Replace spark plug.TO.DRFT. ☞ TROUBLESHOOTING. always complete "BEFORE REPAIR PROCEDURE" and "AFTER REPAIR PROCEDURE" described in this manual. High: Inspect pressure regulator for high pressure cause. Remove the spark plug. Is strong blue spark visible? (Compare with normal cylinder) Carry out fuel line pressure inspection. low compression Faulty spark plug Procedure 1. Fuel can ignite and cause serious injuries or death and damage. • Fuel line spills and leaks are dangerous. 2.

ACTION STEP 1 2 3 Is air cleaner element free of restriction? Carry out spark test. Fuel Line Pressure Inspection Is fuel line pressure correct? Fuel line pressure 270—310 kPa {2. • Fuel line spills and leaks are dangerous. Go to next step. Inspect for open circuit between suspected fuel injector terminal and PCM connector terminal.INDEX TROUBLESHOOTING SYMPTOM 2 POSSIBLE CAUSE STEP 1 Grayish white with specific plug • • Air/fuel mixture—Insufficient fuel injection volume Faulty spark plug INSPECTION Inspect spark plug for following: • Heating value • Air gap Is spark plug okay? Remove suspected fuel injector.2 kgf/cm 2.DRFT. Repair or replace malfunctioning parts. Zero or low: Inspect fuel pump circuit. MANUAL TO. To prevent this. Repair or replace malfunctioning parts. Go to next step. AFTER REPAIR PROCEDURE INSPECTION RESULTS Yes No Yes No Yes No Go to next step.7—3. Replace spark plug.TO. High: Inspect pressure regulator for high pressure cause. Inspect for clogged main fuel line. Repair or replace malfunctioning parts. Is compression correct? Yes No Repair or replace malfunctioning parts. BEFORE REPAIR PROCEDURE ☞ FUEL SYSTEM. Inspect for clogging in exhaust system.INDEX RANG.REPAIR MANUAL PAGES. It can easily ignite.BACK. MODEL . Replace air cleaner element. Inspect for fuel pump relief valve open. PID/DATA MONITOR INSPECTION • MAF V • ECT • FHO2S (When engine can be started) Are PIDs okay? Carry out purge control inspection. (When engine can be started) Is purge control correct? Carry out compression inspection. Go to next step. ☞ TROUBLESHOOTING. causing serious injury and damage. Inspect for following: ☞ FUEL SYSTEM. Read following warnings before performing fuel system service: • Fuel vapor is hazardous. ACTION 2 No Replace fuel injector.CHAPTER. 6 F1-116 CONTINUED . ENGINE SYSTEM INSPECTION. ☞ FUEL SYSTEM. 37—45 psi} 4 Inspect following PIDs: ☞ CONTROL SYSTEM. SYMPTOM 3 POSSIBLE CAUSE Warning Following troubleshooting flowchart contains fuel system diagnosis and repair procedures. FUEL INJECTOR INSPECTION • Resistance • Fuel injection volume Are all above items okay? Wet/carbon stuck on all plugs • • • • Spark—Spark weak Air/fuel mixture—Too rich Compression—Low compression Clogging in intake/exhaust system RESULTS Yes No Yes Go to next step. FROM. Inspect for clogged fuel return line. Is strong blue spark visible at each cylinder? Carry out fuel line pressure inspection. Inspect for fuel leakage inside pressure regulator. 5 Yes No Yes No Go to next step. Fuel can ignite and cause serious injuries or death and damage. Always keep sparks and flames away from fuel. always complete "BEFORE REPAIR PROCEDURE" and "AFTER REPAIR PROCEDURE" described in this manual. Fuel can also Irritate skin and eyes.

CHAPTER. Fuel can also irritate skin and eyes. always complete "BEFORE REPAIR PROCEDURE" and "AFTER REPAIR PROCEDURE" described in this manual. STEP 1 When engine cannot be started. causing serious injury and damage. AFTER REPAIR PROCEDURE INSPECTION RESULTS Yes No Yes ACTION Repair or replace malfunctioning parts.DRFT. FROM. It can easily ignite. Inspect for clogged fuel return line.TO. 37—45 psi} 2 No CONTINUED F1-117 . Is air sucked in from intake-air system? Carry out fuel line pressure inspection. Fuel Line Pressure Inspection Is fuel line pressure correct? Fuel line pressure 270—310 kPa {2. Read following warnings before performing fuel system service: • Fuel vapor is hazardous. Always keep sparks and flames away from fuel. MANUAL TO. inspect intake-air system for air leakage. Fuel can ignite and cause serious Injuries or death and damage. • Fuel line spills and leaks are dangerous. MODEL . carry out intake manifold vacuum inspection. Go to next step. Inspect for fuel pump relief valve open. When engine can be started. ☞ TROUBLESHOOTING.7—3.INDEX RANG. ☞ FUEL SYSTEM.2 kgf/cm 2. ENGINE SYSTEM INSPECTION. Inspect following PIDs: ☞ CONTROL SYSTEM. Inspect for fuel leakage inside pressure regulator. PID/DATA MONITOR INSPECTION • MAF V • ECT • FHO2S (When engine can be started) Inspect for PCM GND condition. To prevent this.BACK. Inspect for clogged main fuel line.REPAIR MANUAL PAGES. High: Inspect pressure regulator for high pressure cause. BEFORE REPAIR PROCEDURE ☞ FUEL SYSTEM. Zero or low: Inspect fuel pump circuit.INDEX TROUBLESHOOTING SYMPTOM 4 Grayish white with all plugs • Air/fuel mixture—Too lean POSSIBLE CAUSE Warning Following troubleshooting flowchart contains fuel system diagnosis and repair procedures.

5 V or more.5 V or more difference between the sensor and NGS voltages. Turn the ignition on and run it at idle. any sudden change in monitor input signals that is not consciously created by the driver can be judged as unusual. You can assume that any signals that are out of specifications by a wide margin are unusual. misreading may occur. (1) If the #1 terminal voltage and the NGS monitor voltage are the same. • Compare the NGS monitor voltage with the measurement voltage using the DIGITAL MEASUREMENT SYSTEM function. MANUAL TO. leading to problems with the vehicle. F1-118 CONTINUED . 1.BACK. (Refer to procedures below) 3. Variable resistance type 1 (Throttle position (TP) sensor and variable resistor (Except Europe)) Input Signal System Investigation Procedure 1. Repair or replace the defective part.DRFT. When measuring voltage. Failure to do this may result in deterioration of the harness or terminal from water damage. use the PID/DATA MONITOR AND RECORD function to inspect the input signal system relating to the problem. After connecting the pin to a waterproof coupler. When recreating the problem. is added to it. Investigate the input signal system 1. • • When plunger is stuck When the plunger is stuck. inspect the waterproof connector for cracks. Find an unusual signal. If there are any. or to the engine itself. inspect the following points concerning the PCM connector. attach the tester GND to the GND of the PCM that is being tested. When you get an unusual signal. If this is not done. pulse convergence is smooth because no induced electromotive voltage B is generated. Locating the source of unusual signals Caution: When normal Counter electromotive voltage A. MODEL . Finding unusual signals While referring to the diagnostic trouble code inspection section of the on-board diagnostic system. FROM. 4. Confirm that the unusual signal has been erased. generated when the threeway solenoid valve or the fuel injector is turned off from on. 2. measure the #1 PCM terminal voltage. (1) If there is a 0. Female terminal opening loose Coupler (pin holder) damage Pin discoloration (blackness) • Harness/pin crimp is loose or disconnected.REPAIR MANUAL PAGES.INDEX RANG. (Refer to procedures below) 2. When you get an unusual signal. If you use another tester. • • • 2. measure the #2 sensor terminal voltage. (2) If there is a difference of 0. shows irregular convergence because induced electromotive voltage B. Locate its source. proceed to the next step.TO. inspect the harness for open or short circuits. the measured voltage and actual voltage may differ. inspection such as stuck solenoid valve is made possible without actually removing parts.CHAPTER. generated by the plunger return operation. use sealant to fix them. confirming continuity and measuring the voltage.INDEX TROUBLESHOOTING Inspection Using an Oscilloscope (Reference) Purpose Using an oscilloscope.

CHAPTER. measure the #2 sensor terminal voltage. Investigate the GND system 1. When you get an unusual signal. inspect the following points concerning the PCM connector.REPAIR MANUAL PAGES. When you get an unusual signal. Variable resistance type 2 (Mass air flow (MAP) sensor) (2) If the sensor and NGS voltages are the same. FROM. inspect the following points on the sensor connector. (2) If the #1 terminal voltage and the NGS monitor voltage are the same. 2. inspect for the following. Confirm that terminal sensor #4 is at 0 V. inspect the following points concerning the PCM connector. inspect the harness for open or short circuits. (1) Female terminal opening looseness (2) Coupler (pin holder) damage (3) Pin discoloration (blackness) (4) Harness/pin crimp is loose or disconnected. CONTINUED F1-119 . 2. proceed to next investigation below.BACK. Investigate the GND system 1. measure the #1 PCM terminal voltage.INDEX TROUBLESHOOTING (2) If the sensor and NGS voltages are the same. (1) If it is at 0 V. inspect the sensor. (1) If the measured voltage on the #3 terminal is 5 V. MANUAL TO. (3) Female terminal opening looseness (4) Coupler (pin holder) damage (5) Pin discoloration (blackness) (2) If the #3 terminal measures other than 5 V. proceed to the next step. replace the sensor. (3) If there is a 0. Confirm that terminal sensor #5 is at 0 V. If there are no problems. inspect for the following. If necessary. Thermistor type (Intake air temperature (IAT) and engine coolant temperature (ECT) sensors) Investigate the input signal system 1.TO. If not at 0 V. inspect for the following. (1) If the measured voltage on the #3 terminal is B+.5 V or more difference between the sensor and NGS voltages. If there is no problem. MODEL . If there are no problems.5 V or more. inspect the following points concerning the sensor connector. proceed to next investigation below. • Female terminal opening looseness • Coupler (pin holder) damage • Pin discoloration (blackness) • Harness/pin crimp is loose or disconnected. • Female terminal opening looseness • Coupler (pin holder) damage • Pin discoloration (blackness) • Harness/pin crimp is loose or disconnected. • Female terminal opening looseness • Coupler (pin holder) damage • Pin discoloration (blackness) • Harness/pin crimp is loose or disconnected. When you get an unusual signal. measure the #1 PCM terminal voltage. Investigate the standard power supply system (1) Confirm that the #3 terminal is at 5 V.DRFT. proceed to the next step. (2) If there is a difference of 0. (2) If not. • Open or short circuit in harness • Harness/pin crimp is loose or disconnected. Investigate the input signal system 1. inspect the following points concerning the sensor connector. Investigate the electrical supply system 1. If necessary.5 V or more. (3) If there is a difference of 0. (1) If the #1 terminal voltage and the NGS monitor voltage are the same.5 V or more difference between the sensor and NGS voltages. inspect the following points on the sensor connector. proceed to next investigation below. When you get an unusual signal. Open or short circuit in harness Female terminal opening looseness Coupler (pin holder) damage Pin discoloration (blackness) Harness/pin crimp is loose or disconnected. measure the #2 sensor terminal voltage. • Open or short circuit in harness • Harness/pin crimp is loose or disconnected. (1) (2) If it is at 0 V. If there is no problem. inspect the harness for open or short circuits. • Female terminal opening looseness • Coupler (pin holder) damage • Pin discoloration (blackness) (2) If the #3 terminal measures other than B+. proceed to next investigation below. inspect the sensor. Confirm that the sensor #3 terminal is B+. Open circuit in harness Female terminal opening looseness Coupler (pin holder) damage Pin discoloration (blackness) Harness/pin crimp is loose or disconnected. inspect for the following.INDEX RANG. replace the sensor. (1) If there is a 0.

inspect the sensor. (1) If it is at 0 V. inspect for the following. Start the engine and run it at idle. Vehicle speed sensor (VSS) 2. 2. inspect for the following. Investigate the GND system 1. replace the sensor. Confirm that the #3 terminal switch voltage is at 0 V. (1) If it is at 0 V or 5 V.CHAPTER. inspect for the following points concerning the sensor connector. • Open circuit in harness • Female terminal opening looseness • Coupler (pin holder) damage Intake Manifold Vacuum Inspection 1. proceed to symptom troubleshooting No. (1) If it is at 0 V or 5 V. Measure the #2 sensor terminal voltage and confirm that it is at 0 V or 5 V when the ignition switch is on and the engine at idle.INDEX RANG. If there are no problem. inspect the following points concerning the PCM connector. CONTINUED F1-120 . If not as specified. inspect the sensor. inspect the following. 3. • • Pin discoloration (blackness) Harness/pin crimp is loose or disconnected. FROM. 4. inspect the following points concerning the sensor connector. Connect a vacuum gauge to the intake manifold and measure the intake manifold vacuum. MODEL . If necessary. (2) If not. • Main relay • Harness and connector between ignition switch and main relay 1. Verify air intake hoses are installed properly. (2) If not.26 "Intermittent Concerns". (2) If not.BACK.INDEX TROUBLESHOOTING (2) If the sensor and NGS voltages are the same. If there is no operating sound.DRFT. inspect for the following: Air suction at throttle body. • Air suction can be located by engine speed change when lubricant is sprayed on the area where suction is occurring.TO. intake manifold and • PCV valve installation points Fuel injector insulator • Accelerator cable free play • Engine compression (Refer to section B1.26 "Intermittent Concerns".) • Note 3. If there are no problems.REPAIR MANUAL PAGES. Specification More than 60 kPa {450 mmHg. • Female terminal opening looseness • Coupler (pin holder) damage • Pin discoloration (blackness) • Harness/pin crimp is loose or disconnected. MANUAL TO. If there are no problems. Open circuit in harness Female terminal opening looseness Coupler (pin holder) damage Pin discoloration (blackness) Harness/pin crimp is loose or disconnected. proceed to symptom troubleshooting No. Disconnect the vacuum hose between the intake manifold and purge solenoid valve on the intake manifold side. • Female terminal opening loose • Coupler (pin holder) damage • Pin discoloration (blackness) • Harness/pin crimp is loose or disconnected. If necessary. Confirm that terminal sensor #3 is at 0 V. proceed to next step. • Female terminal opening looseness • Coupler (pin holder) damage • Pin discoloration (blackness) • Harness/pin crimp is loose or disconnected. proceed to next step. Verify that the main relay clicks when the ignition switch is turned to on and off. 18 inHg} 5. proceed to next investigation below. replace the sensor. ENGINE SYSTEM INSPECTION Main Relay Operation Inspection 1. Measure the #1 PCM terminal voltage and confirm that it is at 0 V or 5 V when the ignition switch is on and the engine is at idle. (2) If not. (1) If it is at 0 V. 2.

(5) Change the duty value of the IAC valve to 100% using the IACV PID. 3 * : A/C switch and fan switch are on.CHAPTER. 5. • ECT • IACV • RPM Verify that the engine is cold. (Refer to FUEL SYSTEM. Select the PID/DATA MONITOR AND RECORD function on the NGS display. Load condition 2 (3) 4. Verify that DTC P0505 is not displayed. If the engine condition does not change.) 1. carry out the following. Fuel can also irritate skin and eyes. 6. 2. Select the PID/DATA MONITOR AND RECORD function on the NGS display. MANUAL TO. 2 * : Steering wheel is fully turned.TO. (2) Connect the SSTs (NGS tester) to DLC. FROM. inspect the following. Fuel can ignite and cause serious injuries or death. Note • Excludes temporary idle speed drop just after the electrical loads are turned on. ① If the idle speed increases. Disconnect the negative battery cable.DRFT.BACK. Turn the electrical loads on and verify that the engine speed is within the specification. (4) Select the SIMULATION TEST function on the NGS display. • IAC valve air passage • Open or short circuit between IAC valve connector terminals and PCM connector terminal 2W Warm up the engine to normal operating temperature and run it at idle. Select the following PIDs. then start the engine. Select the following PIDs. ② If the idle speed does not change. • A/C SW • IAC V • PSP SW • RPM 7. always complete the "BEFORE REPAIR PROCEDURE". • To prevent this. 2. 4. • A/C switch inspection • PSP switch inspection • IAC valve inspection Fuel Line Pressure Inspection Warning • Fuel line spills and leakage are dangerous. • ECT sensor inspection • IAC valve inspection 5. If the engine speed does not decrease or decreases slowly. 3. 2. CONTINUED . Verify that the engine speed decreases as the engine warms up. (6) Verify that the idle speed increases. Connect a fuel pressure gauge between the fuel filter and fuel distributor. BEFORE REPAIR PROCEDURE. If DTC P0505 is shown. 6. carry out DTC inspection. MODEL . carry out the following.REPAIR MANUAL PAGES. replace the PCM. Start the engine and run at idle. 3.INDEX TROUBLESHOOTING Idle Air Control (IAC) Inspection Engine coolant temperature (ECT) compensation inspection 1. Connect the SSTs (NQS tester) to DLC. 8. P/S ON* 700—800 (750 ± 50) A/CON*3 *1 Excludes temporary idle speed drop just after the electrical loads (E/L) are turned on. If not as specified. (1) Connect the IAC valve connector. do as follows. Disconnect the IAC valve connector and verify that the engine rotation changes.INDEX RANG. Engine speed (rpm) Idle-up speed (rpm)* 1 Load compensation inspection 1.

FROM. F1-122 CONTINUED . 2. inspect the fuel pump maximum pressure. 7. Turn the ignition switch on for approx. 10 sec. Short the DLC terminal F/P to body GND using a jumper wire. Connect the negative battery cable. 4. Disconnect the negative battery cable. inspect the fuel pump maximum pressure. MANUAL TO. If the pressure is lower than specified. 6. measure the fuel line pressure while pinching the return hose. Fuel can ignite and cause serious injuries or death. Specification 2 270—310 kPa {2. 8.REPAIR MANUAL PAGES. inspect fuel return hose or the pressure regulator for clogging. Carefully connect the specified terminals only. 5. If the fuel pump maximum pressure is normal. (Refer to FUEL SYSTEM.) 1. Connect the negative battery cable. to operate the fuel pump body. Turn the ignition switch on and measure the fuel line pressure. If the pressure is higher than specified. Turn off the ignition switch and disconnect the jumper wire. • To prevent this. 39—45 psi} 3. inspect for clogging between fuel pump body and pressure regulator. Connect a fuel pressure gauge between the fuel filter and fuel distributor.BACK. 7. 8.2 kgf/cm . 6.DRFT.INDEX RANG. 4. Observe the fuel pressure after 5 min. Fuel Pressure Hold Inspection Warning • Fuel line spills and leakage are dangerous. Caution • Connecting the wrong DLC terminals may possibly cause a malfunction. inspect the pressure regulator and PRC solenoid valve.7—3. MODEL . 21 psi} • If the fuel line pressure quickly increases.TO.5 kgf/cm . Fuel can also irritate skin and eyes. Short the DLC terminal F/P to body GND using a jumper wire. Carefully connect the specified terminals only.CHAPTER. 5.INDEX TROUBLESHOOTING • If fuel line pressure gradually increases. If normal. If the pressure is lower than specified. BEFORE REPAIR PROCEDURE. always complete the "BEFORE REPAIR PROCEDURE". measure the fuel line pressure while pinching the return hose. Caution • Connecting the wrong DLC terminals may possibly cause a malfunction. Specification 2 More than 150 kPa {1. 3. Turn off the ignition switch and disconnect the jumper wire.

30—36} 270—310 {2. PRESSURE REGULATOR REMOVAL/INSTALLATION. ⑤ Turn the PRC solenoid valve from off to on and inspect if the operation sound of the valve is heard. 4.1—2. MODEL .6. psi}] 210—250 {2. of hot start Judgment CONTINUED F1-123 .) • If fuel line pressure does not hold. Measure the fuel line pressure under the following conditions.INDEX RANG. Select the SIMULATION TEST function on the NGS display.TO.INDEX TROUBLESHOOTING Inspection 1 1.6. ⑦ It the operating sound is not heard. inspect the PRC solenoid valve. 6.DRFT. Fuel pressure [kPa {kgf/cm 2. 30—36} Normal 210—250 {2.) 1. (Refer to FUEL SYSTEM. inspect the following. Fuel can also irritate skin and eyes. 30—36} 270—310 {2.7—3.7—3.2. If the fuel line pressure holds. BEFORE REPAIR PROCEDURE. • ECT. (1) If the pressure changes. 2. Turn the PRC solenoid valve from off to on and inspect if the fuel pressure changes. 4. Connect the SSTs (NGS tester) to the DLC. ④ Press START. ① Select the SIMULATION TEST function on the NGS display. replace the pressure regulator. Select PRCV PID. Press START. MANUAL TO. Start the engine and let it idle. 3&—45} 2. do as follows.1—2.CHAPTER. Inspection 2 1. Select the SIMULATION TEST function on the NGS display. Disconnect the negative battery cable. 3. Fuel can ignite and cause serious injuries or death.) (2) If the pressure does not change. inspect the fuel leakage from fuel line and fuel injector. (Pressure regulator—PRC solenoid valve—intake manifold) (2) If the operating sound is not heard.6. always complete the "BEFORE REPAIR PROCEDURE". ② Select IDLING TEST mode. 39—45} 210—250 {2. Connect the negative battery cable. Connect a fuel pressure gauge between the fuel filter and fuel distributor. inspect for a loose or damaged vacuum hose.2. Turn the PRC solenoid valve from off to on using the PRCV PID and inspect if the operating sound is heard. 5. Pressure Regulator Control Inspection Warning • Fuel line spills and leakage are dangerous. • To prevent this. 7. of hot start After 120 sec. 3. (1) If the operating sound is heard. • 2. inspect the pressure regulator. (Refer to FUEL SYSTEM. IATDC and TP V PIDs (Refer to CONTROL SYSTEM. ⑥ If the operating sound is heard.1—2. ③ Select PRCV PID. inspect the PRC solenoid valve) Specifications Condition Idling During 120 sec. 4. PID/DATA MONITOR INSPECTION. Select IDLING TEST mode.BACK. Connect the SSTs (NGS tester) to the DLC. FROM. Not Normal (Perform Inspection 1) Not Normal (Perform Inspection 2) Turn the ignition switch on. 3.REPAIR MANUAL PAGES.

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TROUBLESHOOTING
Fuel Injector Operation Inspection
STEP INSPECTION 1 While cranking engine, inspect for fuel injector operating sound at each cylinder using a soundscope. Is operating sound heard? RESULTS ACTION Yes Fuel injector operation is okay. Not heard at all cylinders: No Go to next step. Not heard at some cylinders: Go to Step 3. Yes Inspect following: • Fuel injector power system related wiring harnesses and connectors • PCM connectors • Fuel injector GND and related wiring harnesses and connectors Repair or replace malfunctioning parts. Go to next step. Replace fuel injector. Inspect PCM terminal voltage of fuel injector signal. Repair or replace malfunctioning parts.

2

Carry out main relay operation inspection. Is main relay operation okay?

No 3 Change fuel injector connector of not operating fuel injector and operating fuel injector. Is operating sound heard? Are wiring harnesses and connectors of not operating fuel injector okay? (Open or short) Yes No Yes No

4

Fuel Cut Control Inspection 1. Warm up engine and let it idle. 2. Turn off the electrical loads and A/C switch. 3. Connect the SSTs (NGS tester) to the DLC.

Fuel Pump Operation Inspection 1. Connect the SSTs (NGS tester) to the DLC.

4. 5. 6. 7.

8.

Select the PID/DATA MONITOR AND RECORD function on the NGS display. Select RPM and INJ PIDs. Press START. Monitor both PIDs while performing the following steps. (1) Depress the accelerator pedal and increase the engine speed to 4000 rpm. (2) Release the accelerator pedal (brake pedal is not depressed) and inspect that the fuel injector duration time is 0 msec., and 2—5 msec. when the engine speed drops below 1200 rpm. If not as specified, carry out the following. • ECT sensor inspection • Neutral/clutch switch inspection

2. 3. 4. 5. 6.

Remove the fuel-filler cap. Turn the ignition switch on. Select the SIMULATION TEST function on the NGS display. Turn the fuel pump relay from off to on using the FP RLY PID and inspect if the operating sound is heard. If no operating sound is heard, measure the voltage at harness side fuel pump unit connector terminal B. Specification Battery positive voltage (Ignition switch on)

CONTINUED

F1-124

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TROUBLESHOOTING
7. If the voltage is as specified, inspect the following. • Fuel pump continuity • Fuel pump GND • Wiring harness between fuel pump relay and PCM terminal 1 H If not as specified, inspect the following. 1. Fuel pump relay 2. Wiring harness and connector (Main relay—fuel pump relay—fuel pump unit) 4. 5. Increase the engine speed and verify the ignition timing is advanced. If the ignition timing is not advanced, carry out the following. • CMP sensor inspection • MAP sensor inspection

8.

Fuel Pump Control Inspection 1. Connect the SSTs (NGS tester) to the DLC.

2. 3. 4. 5. 6. 7.

Turn the ignition switch on. Select the SIMULATION TEST function on the NGS display. Select IG ON TEST mode. Select FP RLY PID. Press START. Turn the fuel pump relay from off to on and inspect if the operating sound of the fuel pump relay is heard.

8. 9.

If no operating sound is heard, inspect the fuel pump relay. If the fuel pump relay is normal, inspect the following. • Wiring harnesses and connectors (Main relay—fuel pump relay—PCM)

Ignition Timing Control Inspection 1. Connect a timing light to the engine. 2. Crank the engine. 3. Verify that the timing mark (yellow) on the crankshaft pulley is within the specification. Specification BTDC 9°—11°(10° ± 1°)

CONTINUED F1-125

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TROUBLESHOOTING
Spark Test 1. Remove the fuel pump relay. 2. Verify that each high-tension lead and connector is connected properly. 3. Inspect the ignition system in the following procedure. Warning • High voltage in the ignition system can cause strong electrical shock which can result in serious injury. Avoid direct contact to the vehicle body during the following spark test. STEP INSPECTION 1 Remove high-tension lead from spark plug. Hold high-tension lead with pliers installed 5—10 mm {0.20—0.39 in} from GND. Crank the engine and verify that there is a strong blue spark. (Inspect each cylinder.) 2 Is high-tension lead resistance correct? RESULTS ACTION Yes Ignition system is okay. No Some cylinders do not spark: Go to next step. All cylinders do not spark: Go to Step 3. Inspect for cracks or damage of high-tension lead, distributor and Ignition coil. Replace the high-tension lead. Repair or replace connector. Go to next step. Go to next step. Replace igniter. Go to next step. Replace ignition coil. Go to next step. Replace distributor cap or rotor. Inspect for open or short in wiring harness and connector of CMP sensor. Repair or replace malfunctioning part.

Yes No

3 4 5 6 7

Does PCM or ignition coil connector have poor connection? Is igniter okay? Is ignition coil winding resistance okay? Are distributor cap and rotor okay? Are following parts okay? • CMP sensor • PCM terminal 2F voltage Specification Approx. 1.5 V

Yes No Yes No Yes No Yes No Yes

No

CONTINUED

F1-126

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TROUBLESHOOTING
Purge Control Inspection 1. Start the engine. 2. Disconnect the vacuum hose between the purge solenoid valve and the charcoal canister. 3. Put a finger to the purge solenoid valve and verify that there is no vacuum applied when the engine is cold. 4. If there is a vacuum, inspect the following. • Wiring harness and connectors (Purge solenoid valve—PCM terminal 2X) • Purge solenoid valve 5. Warm up the engine to the normal operating temperature. 6. Stop the engine. 7. Connect the SSTs (NGS tester) to DLC. A/C CUT-OFF CONTROL INSPECTION 1. Start the engine. 2. Turn the A/C switch and fan switch on. 3. Verify that the A/C compressor magnetic clutch actuates. 4. If it does not actuate, go to symptom troubleshooting No.22 "A/C does not work sufficiently". Note • Specification of A/C cut-off control time is from 2 to 5 seconds. Fully open the throttle valve in a short period and verify that the A/C compressor magnetic clutch does not actuate. If it actuates, inspect the following. (1) Connect the SSTs (NGS tester) to DLC.

5.

6.

8. 9. 10. 11. 12. 13. 14. 15. 16.

Turn the ignition switch on. Select the PID/DATA MONITOR AND RECORD function on the NGS display. Select ECT PID. Verify that the engine coolant temperature is above 60°C {140°F}. If the SSTs (NGS tester) indicates below 60 °C {140 °F}, carry out the ECT sensor inspection. Select the SIMULATION TEST function on the NGS display. Select PRGV PID. Press START. Increase the duty value of the purge solenoid valve to 50% and inspect if the operating sound of the valve is heard. (1) If the operating sound is heard, inspect the loose or damaged vacuum hose. (Intake manifold— purge solenoid valve—charcoal canister) (2) If the operating sound is not heard, carry out the purge solenoid valve inspection.

(2) (3) (4)

Turn the A/C switch off. Turn the ignition switch on. Select the SIMULATION TEST function on the NGS display. (5) Select IG ON TEST mode. (6) Select A/C RLY PID (7) Press START. (8) Turn the A/C relay from off to on and inspect if the operating sound of the relay is heard. (9) If the operating sound is heard, inspect TP V PID. (10) If the operating sound is not heard, inspect the following. • /C relay • Open or short to GND circuit in wiring harnesses and connectors (Main relay—A/C relay—PCM terminal 1J) • A/C related parts

CONTINUED

F1-127

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FUEL AND EMISSION CONTROL SYSTEMS (WL, WL Turbo)
ENGINE TUNE-UP . . . . . . . . . . . . . . . . . . . . . . . . . F2– 2 ENGINE TUNE-UP PREPARATION . . . . . . . . F2– 2 IDLE SPEED ADJUSTMENT . . . . . . . . . . . . . . F2– 2 IDLE-UP SPEED ADJUSTMENT . . . . . . . . . . . F2– 2 INJECTION TIMING ADJUSTMENT . . . . . . . . F2– 3 INTAKE-AIR SYSTEM . . . . . . . . . . . . . . . . . . . . . . F2– 4 VACUUM HOSE ROUTING DIAGRAM . . . . . F2– 4 INTAKE-AIR SYSTEM REMOVAL/INSTALLATION . . . . . . . . . . . . . . F2– 5/7 TURBOCHARGER INSPECTION . . . . . . . . . . F2– 8/9 GLOW PLUG REMOVAL/INSTALLATION . . . F2– 9 GLOW PLUG INSPECTION . . . . . . . . . . . . . . . F2– 9 GLOW PLUG RELAY REMOVAL/INSTALLATION . . . . . . . . . . . . . . F2– 9 GLOW PLUG RELAY INSPECTION . . . . . . . . F2–10 GLOW PLUG CORD INSPECTION . . . . . . . . F2–10 ACCELERATOR PEDAL REMOVAL/INSTALLATION . . . . . . . . . . . . . . . . . F2–10/11 ACCELERATOR CABLE INSPECTION/ADJUSTMENT . . . . . . . . . . . . F2–11 IDLING KNOB, IDLING CABLE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . F2–11 FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . F2–12 BEFORE REPAIR PROCEDURE . . . . . . . . . . F2–12 AFTER REPAIR PROCEDURE . . . . . . . . . . . . F2–12 FUEL TANK REMOVAL/INSTALLATION . . . . F2–13/15 FUEL FILTER DISASSEMBLY/ ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . F2–15/16 FUEL GAUGE SENDER UNIT REMOVAL/INSTALLATION . . . . . . . . . . . . . . F2–16 FUEL GAUGE SENDER UNIT INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . F2–16 FUEL FILTER AIR BLEEDING . . . . . . . . . . . . . F2–16 SEDIMENTOR WATER DRAINING . . . . . . . . . F2–16 SEDIMENTOR SWITCH INSPECTION . . . . . F2–16/17 FUEL WARMER INSPECTION . . . . . . . . . . . . F2–17 FUEL INJECTION PUMP (FIP) INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . F2–17 FUEL INJECTION PUMP (FIP) REMOVAL/INSTALLATION . . . . . . . . . . . . . . F2–17/18 INJECTION NOZZLE REMOVAL/INSTALLATION . . . . . . . . . . . . . . F2–18 INJECTION NOZZLE DISASSEMBLY/ASSEMBLY . . . . . . . . . . . . . F2–19 INJECTION NOZZLE INSPECTION . . . . . . . . F2–19/20 FUEL CUT VALVE (FCV) REMOVAL/INSTALLATION . . . . . . . . . . . . . . F2–20 FUEL CUT VALVE (FCV) INSPECTION . . . . . F2–20/21 FICD SOLENOID VALVE NO.1, NO.2 INSPECTION F2–21 TIMER CONTROL VALVE (TCV) INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . F2–22 EXHAUST SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . F2–23 EXHAUST SYSTEM INSPECTION . . . . . . . . . F2–23 EXHAUST SYSTEM REMOVAL/INSTALLATION . . . . . . . . . . . . . . F2–23/25 EMISSION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . F2–25 ROLLOVER VALVE INSPECTION . . . . . . . . . F2–25 EVAPORATIVE CHAMBER INSPECTION . . . F2–25 EGR VALVE INSPECTION . . . . . . . . . . . . . . . . F2–26 EGR SOLENOID VALVE INSPECTION . . . . . F2–26 EGR PIPE, EGR VALVE REMOVAL/INSTALLATION . . . . . . . . . . . . . . . . . F2–26 CONTROL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . F2–27 COMPONENT PARTS . . . . . . . . . . . . . . . . . . . . F2–27 POWERTRAIN CONTROL MODULE (PCM) REMOVAL/INSTALLATION . . . . . . . . . . . . . . F2–28 POWERTRAIN CONTROL MODULE (PCM) INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . F2–28/31 NE SENSOR INSPECTION . . . . . . . . . . . . . . . F2–32 ENGINE COOLANT TEMPERATURE (ECT) SENSOR INSPECTION . . . . . . . . . . . . . . . . . F2–32/33 IDLE SWITCH INSPECTION . . . . . . . . . . . . . . F2–33 CONTROL LEVER POSITION SENSOR INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . F2–33/34 ON-BOARD DIAGNOSTIC SYSTEM . . . . . . . . . F2–35 DTC READING PROCEDURE . . . . . . . . . . . . . F2–35 AFTER REPAIR PROCEDURE . . . . . . . . . . . . F2–35 DTC INSPECTION . . . . . . . . . . . . . . . . . . . . . . . F2–36/38 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . F2–39 FOREWORD . . . . . . . . . . . . . . . . . . . . . . . . . . . . F2–39 TROUBLESHOOTING ITEM TABLE . . . . . . . . F2–39 SYMPTOM TROUBLESHOOTING . . . . . . . . . F2–40/60 SYSTEM INSPECTION . . . . . . . . . . . . . . . . . . . F2–61/64

CONTINUED

F2–1

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ENGINE TUNE-UP

ENGINE TUNE-UP
ENGINE TUNE-UP PREPARATION 1. Warm up the engine to normal operating temperature. 2. Turn the all electrical loads off. 3. Connect a tachometer. IDLE SPEED ADJUSTMENT WL 1. Perform “Engine tune-up preparation”. 2. Verify that the idle speed is within the specification. Specification 700—740 (720$20) rpm 3. If not within the specification, adjust the idle speed by turning the IAS (idle adjustment screw).
LOCKNUT
5.9—8.8 N·m {60—90 kgf·cm, 53—78 in·lbf}

4. After adjusting the idle speed, tighten the locknut securely. IDLE-UP SPEED ADJUSTMENT 1. Perform “Engine tune-up preparation”. 2. Turn all electrical loads off in neutral shift position. 3. Apply vacuum of –53.3 kPa {–400 mmHg, –15.8 inHg} or over to actuator B, and measure the idle-up speed.
WL
ADJUSTING SCREW C ADJUSTING SCREW B

LOCKNUT B

ACTUATOR A ACTUATOR B

WL, WL Turbo
IAS ADJUSTING SCREW C ADJUSTING SCREW B

LOCKNUT B

4. After adjusting the idle speed, tighten the locknut securely. WL Turbo 1. Perform “Engine tune-up preparation”. 2. Verify that the idle speed is within the specification. Specification General (L.H.D.) : 760—800 (780$20) rpm Europe and UK : 700—740 (720$20) rpm Caution D Turning the idle switch (Europe and UK only) with its connector connected can break the harness. Be sure to disconnect the connector when turning the idle switch more than one rotation. 3. If not as specified, loosen the idle switch locknut and adjust the idle speed by turning the idle switch.
LOCKNUT
11.8—14.7 N·m {120—150 kgf·cm, 104—130 in·lbf}

ACTUATOR A ACTUATOR B

Specification 1200—1500 (1,350$150) rpm 4. If not within the specification, do as follows; (1) Loosen the locknut B. (2) Adjust the idle-up speed by turning the adjusting screw B. (3) Tighten the locknut B. Tightening torque 5.9—8.8 N·m {60—90 kgf·cm, 53—78 in·lbf} 5. Release actuator B to atmosphere and apply vacuum of –53.3 kPa {–400 mmHg, –15.8 inHg} or over to actuator A, and measure the idle-up speed. Specification WL vehicle: 805—855 (830$25) rpm WL Turbo, WL (Europe only): 825—875 (850$25) rpm 6. If not as specified, adjust the idle-up speed by turning adjusting screw C.

IDLE SWITCH

CONTINUED

F2–2

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ENGINE TUNE-UP
INJECTION TIMING ADJUSTMENT Warning D Fuel vapor is hazardous. It can very easily ignite, causing serious injury and damage. Always keep sparks and flames away from fuel. D Fuel line spills and leaks are dangerous. Fuel can ignite and cause serious injuries or death and damage. Fuel can also irritate skin and eyes. To prevent this, always observe the “Fuel Line Safety Procedures”, “Fuel Hose Installation”. Caution D After tightening the FIP mounting nuts and bolt after loosening them, be sure to inspect the timing belt tension. If the belt tension is not inspected, the timing belt and the camshaft may become damaged. (Refer to Section B2, TIMING BELT, TIMING BELT REMOVAL/INSTALLATION, Timing Belt Installation Note.) 6. Turn the crankshaft counterclockwise to approx. 30° BTDC. (Align the SST installation hole on the crankshaft pulley.) 7. Turn the crankshaft lightly right and left, and verify that the dial gauge indicator does not move. Then set the indicator to 0 mm {0 in}. 8. Turn the crankshaft clockwise to position the indicator pin to 10° ATDC (white mark) and read the dial indicator.
INDICATOR PIN BTDC 0° (YELLOW MARK)

ATDC 10° (WHITE MARK)

1. Remove the injection pipes (Refer to FUEL SYSTEM, FUEL INJECTION PUMP (FIP) 9. If not as specified, adjust by loosening the FIP REMOVAL/INSTALLATION.) mounting nut and bolt and turn the FIP. 2. Remove the cooling fan 10. Tighten the FIP mounting nuts and then the bolt. (Refer to Section E, COOLING FAN, COOLING FAN REMOVAL/INSTALLATION.) Tightening torque 3. Turn the crankshaft pulley at slow rotation to align 19—25 N·m {1.9—2.6 kgf·m, 14—18 ft·lbf} the timing mark (BTDC 0° : yellow mark) with MOUNTING NUT indicator pin.
INDICATOR PIN BTDC 0 ° (YELLOW MARK)

Specification 0.95—1.05 mm {0.038—0.041 in} (1.0$0.05 mm {0.039$0.019 in})

MOUNTING BOLT ATDC 10 ° (WHITE MARK)

4. Remove the hydraulic head plug from the injection pump. 5. Mount the SST into the plug hole on the hydraulic head so that the dial indicator probe touches the plunger end of the pump and the dial indicator indicates approx. 2.0 mm {0.079 in}.
49 9140 074

11. Remove the SST. 12. Install the hydraulic head plug and a new gasket. Tightening torque 14—19 N·m {1.4—2.0 kgf·m, 11—14 ft·lbf} 13. Connect the injection pipes. (Refer to FUEL SYSTEM, INJECTION NOZZLE REMOVAL/INSTALLATION.) 14. Bleed the air from the fuel filter. (Refer to FUEL SYSTEM, FUEL FILTER AIR BLEEDING.) 15. Inspect for fuel leakage. 16. Check the timing belt tension. (Refer to Section B2, TIMING BELT, TIMING BELT REMOVAL/INSTALLATION, Timing Belt Installation Note.)

CONTINUED

F2–3

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INTAKE-AIR SYSTEM

INTAKE-AIR SYSTEM
VACUUM HOSE ROUTING DIAGRAM
WL
TO POWER BRAKE UNIT

FICD SOLENOID VALVE No.1 FICD SOLENOID VALVE No.2

FICD ACTUATOR

VACUUM PUMP

WL TURBO

TO POWER BRAKE UNIT FICD SOLENOID VALVE No.2

TO RFW ACTUATOR

4WD ONLY FICD SOLENOID VALVE No.1

EGR VALVE

EGR SOLENOID VALVE

FICD ACTUATOR

VACUUM PUMP

CONTINUED

F2–4

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INTAKE-AIR SYSTEM
INTAKE-AIR SYSTEM REMOVAL/INSTALLATION Warning D When the engine and intake-air system are hot, they can badly burn. Turn off the engine and wait until they are cool before removing the intake-air system. WL 1. Disconnect the negative battery cable. 2. Remove the injection pipe. (Refer to FUEL SYSTEM, INJECTION NOZZLE REMOVAL/INSTALLATION.) 3. Remove in the order indicated in the table. 4. Install in the reverse order of removal.

7.9—10.7 N·m {80—110 kgf·cm, 69.5—95.4 in·lbf}

7.9—10.7 N·m {80—110 kgf·cm, 70—95 in·lbf}

18.7—25.4 {1.9—2.6, 13.8—18.8} 2.0—2.9 N·m {20—30 kgf·cm, 18—26 in·lbf}

2.0—2.9 N·m {20—30 kgf·cm, 18—26 in·lbf} 7.9—11.7 N·m {80—120 kgf·cm, 70—104 in·lbf}

18.7—25.4 {1.9—2.6, 13.8—18.8}

R

8.9—12.7 N·m {90—130 kgf·cm, 79—112 in·lbf}

7.9—11.7 N·m {80—120 kgf·cm, 70—104 in·lbf} N·m {kgf·m, ft·lbf}

1 2 3 4 5

Fresh-air duct Air cleaner Air hose Resonance chamber Air intake pipe

6 7 8 9

FICD solenoid valve No.1 FICD solenoid valve No.2 FICD solenoid valve bracket Intake manifold

CONTINUED

F2–5

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INTAKE-AIR SYSTEM
WL Turbo 1. Disconnect the negative battery cable. 2. Drain the engine coolant from radiator. (Refer to Section E, COOLING SYSTEM, ENGINE COOLANT REPLACEMENT.) 3. Remove the front mud guard. (Refer to Section S, FRONT FENDER PANEL, FRONT FENDER PANEL REMOVAL/INSTALLATION.) 4. Remove the injection pipe. (Refer to FUEL SYSTEM, INJECTION NOZZLE REMOVAL/INSTALLATION.) 5. Remove in the order indicated in the table. 6. Install in the reverse order of removal. 7. Refill the engine coolant to radiator. (Refer to Section E, COOLING SYSTEM, ENGINE COOLANT REPLACEMENT.)
STEP 1

A

4.9 N·m {50 kgf·cm, 43 in·lbf}

4.9 N·m {50 kgf·cm, 43 in·lbf}

8.9—12.7 N·m {90—130 kgf·cm, 79—112 in·lbf}

7.9—11.7 N·m {80—120 kgf·cm, 70—104 in·lbf}

2.0—2.9 N·m {20—30 kgf·cm, 18—26 in·lbf}

7.9—11.7 N·m {80—120 kgf·cm, 70—104 in·lbf} 4.9 N·m {50 kgf·cm, 43 in·lbf}

7.9—11.7 N·m {80—120 kgf·cm, 70—104 in·lbf}

A

8.9—12.7 N·m {90—130 kgf·cm, 79—112 in·lbf} 8.9—12.7 N·m {90—130 kgf·cm, 79—112 in·lbf}

1 2 3 4

Fresh-air duct Air cleaner Air intake hose Air hose

5 6 7 8

Air intake pipe Air hose Charge air cooler Air hose

CONTINUED

F2–6

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INTAKE-AIR SYSTEM

STEP 2

19—25 {1.9—2.6, 14—18}

7.9—10.7 N·m {80—110 kgf·cm, 69.5—95.4 in·lbf}

19—25 {1.9—2.6, 14—18}

19—25 {1.9—2.6, 14—18} 19—25 {1.9—2.6, 14—18}

R R

N·m {kgf·m, ft·lbf}

1 2 3

FICD solenoid valve No.1 FICD solenoid valve No.2 EGR solenoid valve

4 5 6

FICD solenoid valve bracket Air intake pipe Intake manifold

CONTINUED

F2–7

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INTAKE-AIR SYSTEM
TURBOCHARGER INSPECTION Wastegate Actuator Inspection Caution D Compressed air used in the workshop is highly pressurized and can damage the actuator. Adjust the air pressure with a transformer, and inspect the actual pressure by using an air blower before actual use. Stop blowing air if the rod moved.

A

MIRROR TURBOCHARGER

4. Inspect all fins of compressor wheel while rotating the compressor wheel by hand. 5. If the compressor wheel is interfering with the housing, it is likely that more than two fins are damaged, cracked or bent. Replace the turbocharger. Note D If scratches are found inside the housing but the fins are okay, the turbocharger is okay. Scratches are made in the turbocharger made by factory.

1. Disconnect the air hose of the wastegate actuator on the compressor housing side. 2. Apply the compressed air using the air gun. 3. Note the air pressure when the wastegate actuator is moved. Specification 107—115 kPa {1.09—1.18 kgf/cm2, 15.5—16.8 psi}
WASTEGATE ACTUATOR

ROD

4. If not within the specification, replace the turbocharger. (Refer to EXHAUST SYSTEM, EXHAUST SYSTEM REMOVAL/INSTALLATION.) Compressor Wheels Inspection 1. Remove the air hose. (Refer to INTAKE-AIR SYSTEM, INTAKE-AIR SYSTEM REMOVAL/INSTALLATION.) 2. Remove the joint pipe. (Refer to EXHAUST SYSTEM, EXHAUST SYSTEM REMOVAL/INSTALLATION.) 3. Set the small mirror as shown and inspect the compressor wheel from view A. Note D To make work accurate, use a penlight to inspect.

Turbine Wheels Inspection 1. Remove the air hose. (Refer to INTAKE-AIR SYSTEM, INTAKE-AIR SYSTEM REMOVAL/INSTALLATION.) 2. Remove the joint pipe. (Refer to EXHAUST SYSTEM, EXHAUST SYSTEM REMOVAL/INSTALLATION.) 3. Set the small mirror as shown and inspect the turbine wheel from view B. Note D To make work accurate, use a penlight to inspect.

B

MIRROR TURBOCHARGER

4. Inspect all fins of turbine wheel while rotating the turbine wheel by hand.

CONTINUED

F2–8

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INTAKE-AIR SYSTEM
5. If the turbine wheel is interfering with the housing, it is likely that one or more fins are damaged, cracked or bent. Replace the turbocharger. Note D Grinding marks on the shaft are normal. This mark is for adjusting the shaft balance at the factory. GLOW PLUG INSPECTION 1. Remove the glow plug cord. 2. Inspect the resistance between the glow plug terminal and the cylinder head. Specification Glow plug resistance Approx. 0.75 Ω [20 °C {68 °F}]
GLOW PLUG

GRINDING MARK

GLOW PLUG REMOVAL/INSTALLATION 3. If not as specified, replace the glow plug. Caution D Do not damage the heated section of the glow plug. D Do not reuse a glow plug that has been dropped over a height of 10 cm {0.4 in}. D When removing the glow plug, first loosen it over one pitch by using a tool, then loosen by hand. 1. Disconnect the negative battery cable. 2. Remove in the order indicated in the table. 3. Install in the reverse order of removal. GLOW PLUG RELAY REMOVAL/INSTALLATION 1. Disconnect the negative battery cable. 2. Remove glow plug relay. 3. Install the glow plug relay.
8.9—12.7 N·m {90—130 kgf·cm, 79—112 in·lbf}

GLOW PLUG RELAY

7.9—10.7 N·m {80—110 kgf·cm, 69.5—95.4 in·lbf} 0.8—15 N·m {8—15 kgf·cm, 7—13 in·lbf}

4. Connect the negative battery cable.

1 2

Glow plug cord Glow plug

CONTINUED

F2–9

If not as specified.) 2. 14—18} C D 3. MODEL . SYSTEM INSPECTION. replace the glow plug relay. If there is no continuity. 44 in·lbf} N·m {kgf·m. Verify there is continuity at both ends of the glow plug cord. 4. General (R.D. Glow System Inspection. Remove the glow plug relay.REPAIR MANUAL PAGES. replace the glow plug cord.0 N·m {50 kgf·cm. If there is no continuity. 4. FROM. (Refer to Section N. Remove in the order indicated in the table. Repair or replace faulty areas.) A B : Continuity Step 1 2 A B+ B GND 19—25 {1. MANUAL STEERING WHEEL AND COLUMN REMOVAL/INSTALLATION.) If as specified but the System Inspection is failed.CHAPTER.9—2. MANUAL TO.BACK. 2. Verify that the glow plug cord is not broken or bent. Carry out the “Glow system inspection”.TO. Inspect for continuity between terminals C and D of the glow plug relay under the following conditions. 14—18} GLOW PLUG CORD INSPECTION 1.) 3. 2. Install the glow plug relay. D Glow plug relay connector terminal A (2-pin) and PCM connector terminal O to GND. 5.DRFT.H. Continuity Inspection Note D Perform the following test only when directed. inspect following: Open circuit D Power circuit (Glow plug relay connector terminal A (1-pin: R/B) and battery) D Power circuit (Glow plug relay connector terminal A 123456567 (2-pin) and PCM connector terminal O) D GND circuit (Glow plug relay connector terminal A (1-pin: R) and glow plug cord) D GND circuit (Glow plug relay connector terminal B (2-pin) and engine GND) D Signal circuit (Glow plug relay connector terminal A (1-pin: R) and PCM connector terminal I) Short circuit D Glow plug relay connector terminal A (1-pin: R/B) and battery to GND.6. (Refer to GLOW PLUG REMOVAL/INSTALLATION.INDEX RANG. Remove the glow plug cord. Install in the reverse order of removal.6. C D C A D R B 19—25 {1. R 5. Disconnect the negative battery cable. perform the further inspection for the glow plug relay. (Refer to GLOW PLUG RELAY REMOVAL/INSTALLATION.INDEX INTAKE-AIR SYSTEM GLOW PLUG RELAY INSPECTION System Inspection 1. 4. 3. D Glow plug relay connector terminal A (1-pin: R) and PCM connector terminal I to GND. (Refer to TROUBLESHOOTING. Remove the column cover.) 2.9—2. 1. ACCELERATOR PEDAL REMOVAL/INSTALLATION 1. ft·lbf} 1 2 3 4 5 6 7 8 9 10 11 12 13 14 Idling knob Idling cable Brake switch connector Accelerator cable + Installation Note Spring pin Clevis pin E clip Pin Bushing Push rod Clevis Nut Nut Pedal component + Installation Note CONTINUED F2–10 .

then turn the engine switch off. 2.9—10.) Accelerator Cable Installation Note D Carry out the “ACCELERATOR CABLE INSPECTION/ADJUSTMENT” procedure after installing the accelerator cable.) 1 Accelerator cable 1. MODEL . 2 Accelerator pedal 2. (Refer to ACCELERATOR CABLE INSPECTION/ADJUSTMENT.CHAPTER.H. (Refer to Section H.11 in} 3.REPAIR MANUAL PAGES. If not as specified. Warm up the engine. FROM.) ACCELERATOR CABLE INSPECTION/ADJUSTMENT 1. Verify that the accelerator pedal moves in the direction that engine speed increases.H.5—95. IDLING CABLE INSPECTION General (R. LOCKNUT 7. when the idling knob is not turned.INDEX RANG. (Refer to Section P.4 in·lbf} Free play 1—3 mm {0.04—0. CLUTH PEDAL INSPECTION/ADJUSTMENT. Verify that the accelerator pedal returns to the INSPECTION” procedure after installing the pedal idling position when the idling knob is turned to the component.INDEX INTAKE-AIR SYSTEM Except General (R.TO.) D Carry out the “CLUTCH PEDAL INSPECTION” procedure after installing the pedal component. Verify that the accelerator pedal is in the idling + Installation Note position. Measure the free play of the accelerator cable.) IDLING KNOB CONTINUED F2–11 . D Carry out the “BRAKE PEDAL HEIGHT 3. IDLING KNOB.BACK. adjust by turning locknut. when the Pedal Component Installation Note idling knob is turned to the right. MANUAL TO. BRAKE PEDAL HEIGHT INSPECTION. left.D.7 N·m {80—110 kgf·cm. 69.D.DRFT.

Fuel can ignite and cause serious injuries or death and damage. always complete the following “Fuel Line Safety Procedures”.REPAIR MANUAL PAGES. FROM. Fuel Hose Installation D Verify that there is no damage or deformation on the fuel hose and fuel pipe when installing.DRFT. AFTER REPAIR PROCEDURE Warning D Fuel line spills and leaks are dangerous.CHAPTER. To prevent this.INDEX FUEL SYSTEM FUEL SYSTEM BEFORE REPAIR PROCEDURE Warning D Fuel vapor is hazardous. It can very easily ignite. Warning D Fuel line spills and leaks are dangerous.BACK. MODEL . (3) Plug the fuel hose after removal.INDEX RANG. (2) When disconnecting a fuel hose. Fuel Line Safety Procedures D Avoid fuel line spills and leaks by completing the following procedures. (1) Remove the fuel-filler cap and release the pressure in the fuel tank. causing serious injury and damage. CONTINUED F2–12 . MANUAL TO. D Fuel in the fuel system is under high pressure when the engine is not running. Always keep sparks and flames away from fuel. observe “Fuel Hose Installation” described below.TO. Fuel can also irritate skin and eyes. wrap a rag around it to protect against fuel leakage. Fuel can ignite and cause serious injuries or death and damage. When installing the fuel hose.

69. 12—16} R WITHOUT BOX 32—46 {3. 7. DOUBLE CAB 2WD 1.1–2. 105—147 in·lbf} 11.8—16.7 N·m {80—110 kgf·cm.1—2. Disconnect the negative battery cable. ft·lbf} CONTINUED F2–13 . 6.6 N·m {25—47 kgf·cm.) STRETCH CAB 2WD. Complete the “BEFORE REPAIR PROCEDURE”.TO. 2. Remove in the order indicated in the table. Always properly steam clean a fuel tank before repairing it.1 N·m {11—22 kgf·cm.9–10. 24—33} EUROPE DRAIN PLUG 26—32 {2. 10—19 in·lbf} 16—22 {1. 1. Explosion or fire may cause death or serious injury. Complete the “AFTER REPAIR PROCEDURE”. Remove the drain plug and drain the fuel from the fuel tank.6—2.6—2. 10—19 in·lbf} A B SEAL RUBBER R R 2.5—95.) 3. 12—16} 1. Install in the reverse order of removal.1 N·m {11—22 kgf·cm. 22—26 in·lbf} R 11. MODEL . 4.5—3.7. BEFORE REPAIR PROCEDURE.2—4.5—4.INDEX RANG.1 N·m {11—22 kgf·cm.6—3.2—4.3.1–2.3. MANUAL TO. 22—40 in·lbf} 2.DRFT. 10—19 in·lbf} 1.6 N·m {120—170 kgf·cm.8—16.3.1 N·m {11—22 kgf·cm. 24—33} EXCEPT EUROPE N·m {kgf·m. (Refer to FUEL SYSTEM. 10—19 in·lbf} 7. AFTER REPAIR PROCEDURE.CHAPTER. (Refer to FUEL SYSTEM.5 N·m {25—36 kgf·cm.4 in·lbf} WITH BOX R 1.BACK.INDEX FUEL SYSTEM FUEL TANK REMOVAL/INSTALLATION Warning D Repairing a fuel tank that has not been properly steam cleaned can be dangerous.6 N·m {120—170 kgf·cm. Remove the rear flap. FROM.7. 5. 19—23} 32—46 {3.1–2. 105—147 in·lbf} 16—22 {1.REPAIR MANUAL PAGES.

5 N·m {25—36 kgf·cm.8—16.2—4.BACK.INDEX RANG. 10—19 in·lbf} SEAL R RUBBER 7.REPAIR MANUAL PAGES.2—4. MANUAL TO.8—16. 19—23} 32—46 {3. MODEL .5—3.1–2. 24—33} EXCEPT EUROPE N·m {kgf·m.1–2.4 in·lbf} R WITH BOX A B 1.6—3. ft·lbf} 1 2 3 4 5 6 Evaporative chamber (If equipped) Joint hose + Installation Note Breather hose + Installation Note Under guard Fuel hose + Installation Note Fuel tank 7 8 9 10 11 12 13 14 Evaporative hose + Installation Note Fuel gauge sender unit Rollover valve Fuel-filler pipe Dust cover Fuel inlet pipe Check valve (two–way) Evaporative chamber CONTINUED F2–14 .TO. DOUBLE CAB 4WD.INDEX FUEL SYSTEM STRETCH CAB 4WD.9—10.1 N·m {11—22 kgf·cm.5—4. 22—26 in·lbf} 11.7 N·m {80—110 kgf·cm. REGULAR CAB 1. 10—19 in·lbf} 32—46 {3.6 N·m {120—170 kgf·cm.3.1–2.5—95.1—2. 10—19 in·lbf} 1.7. 12—16} 16—22 {1.3.1 N·m {11—22 kgf·cm. 22—40 in·lbf} 2. 105—147 in·lbf} 11.CHAPTER.1 N·m {11—22 kgf·cm. 10—19 in·lbf} R 2.6—2.1 N·m {11—22 kgf·cm. FROM. 69.6 N·m {120—170 kgf·cm.7.3.6—2. 12—16} 1. 105—147 in·lbf} 16—22 {1. 24—33} R WITHOUT BOX EUROPE DRAIN HOSE 26—32 {2.6 N·m {25—47 kgf·cm.DRFT.

39 in} FUEL HOSE Breather Hose Installation Note D Fit each hose onto the respective fittings within the specification. 2. reassemble the fuel filter. (Refer to FUEL SYSTEM. 5. and install clamps as shown. 4. WITH FUEL WARMER WITHOUT FUEL WARMER 19—25 {1.) 6. FROM.39 in} 9—12 mm {0.98 in} 10 mm {0.47 in} VIEW A VIEW B EVAPORATIVE HOSE Fuel Hose Installation Note D Fit each hose onto the respective fittings within the specification.) 3. ft·lbf} 10 mm {0. If fuel leaks. Start the engine and verify that fuel does not leak from the fuel system. FUEL FILTER AIR BLEEDING.36—0. Assemble in the reverse order of removal. 14—18} 10 mm {0.) 7.36—0. Length Joint hose: 35 {1.BACK. Length Evaporative hose: 25 mm {0. AFTER REPAIR PROCEDURE.INDEX RANG.98 in} FUEL FILTER DISASSEMBLY/ASSEMBLY 1.98 in} N·m {kgf·m. Length Breather hose: 25 mm {0. (Refer to FUEL SYSTEM.47 in} 9—12 mm {0. Complete the “BEFORE REPAIR PROCEDURE”.9—2. BEFORE REPAIR PROCEDURE. Complete the “AFTER REPAIR PROCEDURE”. MANUAL TO. (Refer to FUEL SYSTEM. and install clamp as shown. and install clamp as shown. 8. Disassemble in the order indicated in the table.CHAPTER.INDEX FUEL SYSTEM Evaporative Hose Installation Note D Fit each hose onto the respective fittings within the specification. Disconnect the negative battery cable.TO. Length Fuel hose: 25 mm {0.REPAIR MANUAL PAGES.6.4 in} CONTINUED F2–15 . MODEL .39 in} R BREATHER HOSE Joint Hose Installation Note D Fit the joint hose onto the respective fittings within the specification. and install clamps as shown.DRFT. Bleed air from the fuel filter.

WARNING AND INDICATOR SYSTEM. If as specified. Loosen the drain plug located at the bottom of the fuel filter.CHAPTER. 4. (Refer to FUEL SYSTEM. After all the water has been drained. AFTER REPAIR PROCEDURE. FUEL TANK REMOVAL/INSTALLATION) FUEL GAUGE SENDER UNIT INSPECTION (Refer to Section T. Complete the “AFTER REPAIR PROCEDURE”. D Repeat cranking the engine for 30 seconds and Continuity Yes No FLOAT 5. Disconnect the negative battery cable. If not as specified. Fuel Filter Assembly Note D Apply a small amount of fuel to the fuel filter O-ring. Reconnect the negative battery cable.INDEX RANG. Pump the priming pump and drain the water. SEDIMENTOR WATER DRAINING 1.) 7. 3/4 by hand after the O-ring contacts the priming pump. MANUAL TO. (Refer to FUEL SYSTEM.) FUEL FILTER AIR BLEEDING Caution D Continuously cranking the engine for over 30 seconds can damage the battery and the starter. MODEL . 6.INDEX FUEL SYSTEM SEDIMENTOR SWITCH INSPECTION Continuity Inspection Note D Perform the following test only when directed. tighten the drain plug.) 3.) 3. 1.BACK. HARNESS SIDE CONNECTOR (VIEW FROM TERMINAL SIDE) ENGINE SWITCH A B A B C D HARNESS SIDE CONNECTOR (VIEW FROM TERMINAL SIDE) CONTINUED F2–16 . inspect following: Open circuit D GND circuit (Sedimentor switch connector terminal B and body GND) D Power circuit (Sedimentor switch connector terminal A and engine switch connector terminal C) SEDIMENTOR SWITCH A B stop for 5—10 seconds until the engine starts.DRFT. 2. Inspect continuity of the sedimentor switch by using an ohmmeter. (Refer to FUEL SYSTEM. BEFORE REPAIR PROCEDURE. Tighten the sedimentor switch enough to the fuel filter by hand. Drain fuel from the fuel filter. FUEL GAUGE SENDER UNIT INSPECTION. SEDIMENTOR WATER DRAINING. 4. 2. Remove the sedimentor switch.TO. FROM.REPAIR MANUAL PAGES. FUEL GAUGE SENDER UNIT REMOVAL/INSTALLATION (Refer to FUEL SYSTEM. replace the sedimentor switch. Complete the “BEFORE REPAIR PROCEDURE”. Disconnect the negative battery cable. 5. Float Up Down UP DOWN 1 2 3 4 5 6 7 Connector Fuel hose Priming pump Fuel filter + Assembly Note Sedimentor switch + Assembly Note Drain plug Fuel warmer Sedimentor Switch Assembly Note D Apply a small amount of fuel to a new O-ring. Tighten the fuel filter approx.

Timing Belt Installation Note. BEFORE REPAIR (Refer to INTAKE-AIR SYSTEM. TIMING BELT. 9. 19—21} 19—25 {1.5 2. If not as specified. Install the sedimentor switch.BACK. PROCEDURE. TIMING BELT REMOVAL/INSTALLATION. Disconnect the negative battery cable. –7. (Refer to ENGINE TUNE-UP. BEFORE REPAIR 1. ft·lbf} CONTINUED F2–17 . Remove in the order indicated in the table. 25—29 {2.8 inHg} is applied 8. FROM. MANUAL TO.) REMOVAL/INSTALLATION.4 in·lbf} Specification Water temperature °C {°F} 20 {68} Resistance (Ω) 0. AFTER REPAIR PROCEDURE. Remove the fuel warmer.DRFT. Complete the “AFTER REPAIR PROCEDURE”.CHAPTER.6.REPAIR MANUAL PAGES. be sure to inspect the timing belt tension.) 3. (Refer to FUEL SYSTEM. 7.) REMOVAL/INSTALLATION. 14—18} 59—68 {6.TO.5—3.1 cylinder to TDC. D Consult your distributor for disassembly if any FIP A R internal parts are possibly malfunctioning.4—3. Special tools and testers are required when disassembling the FIP. the fuel warmer body is within the specification 6. If the belt tension is not inspected. {–200—–300mmHg. when vacuum of –26. Verify that the resistance between terminal A and 5.) 1. Reconnect the negative battery cable. FUEL WARMER INSPECTION 2. Inspect injection timing. Complete the “BEFORE REPAIR PROCEDURE”. Check the timing belt tension. 44—50} 5.9—–11.9—2. 22—30 in·lbf} A 19—25 {1.0.) 7. 4. to port A of the fuel warmer. FUEL FILTER (Refer to INTAKE-AIR SYSTEM. (Refer to FUEL SYSTEM. INTAKE-AIR SYSTEM DISASSEMBLY/ASSEMBLY.0—7. Set the No.9—10.0 kPa 7. (Refer to FUEL SYSTEM.9—2. INTAKE-AIR SYSTEM PROCEDURE. 69. FUEL FILTER AIR BLEEDING. FUEL INJECTION PUMP (FIP) INSPECTION Caution D FIP is sealed to maintain proper function. MODEL .0. Remove the FICD solenoid valve bracket.INDEX FUEL SYSTEM Short circuit D GND circuit (Sedimentor switch connector terminal B and body GND to power circuit) D Power circuit (Sedimentor switch connector terminal A and engine switch connector terminal C to GND) FUEL INJECTION PUMP (FIP) REMOVAL/INSTALLATION Caution D After removing/installing the FIP. (Refer to Section B2. Bleed air from the fuel filter. (Refer to FUEL SYSTEM. 3. TIMING BELT REMOVAL/INSTALLATION. Repair or replace faulty areas.5—1. With fuel warmer (Refer to FUEL SYSTEM. (Refer to section B2. Install in the reverse order of removal.5—95. 14—18} N·m {kgf·m.TIMING BELT. Disassembling the FIP without special tools and testers will cause a malfunction. 8. Complete the “BEFORE REPAIR PROCEDURE”.6.) 4.) 10.INDEX RANG.) 9. the timing belt and the camshaft may become damaged. Disconnect the negative battery cable. INJECTION TIMING ADJUSTMENT.7 N·m {80—110 kgf·cm.) 6.4 N·m {25—35 kgf·cm.6—–40. replace the fuel warmer.) 2. Timing Belt Installation Note. Remove the air intake pipe.

ft·lbf} Injection pipe Fuel leak pipe Fuel leak washer Injection nozzle + Installation Note Nozzle washer Corrugated gasket + Installation Note INJECTION NOZZLE REMOVAL/INSTALLATION Caution D Cover the outlet of the injection pipe and fuel hose with a rag.TO.0.0. 2. Complete the “AFTER REPAIR PROCEDURE”. INTAKE-AIR SYSTEM REMOVAL/INSTALLATION. BEFORE REPAIR PROCEDURE. MODEL .3. 44—50} 27—32 {2. 20—23} R R R 7 8 9 10 2. 19—21} N·m {kgf·m.0—7. Loosen the FIP pulley locknut.REPAIR MANUAL PAGES. Disconnect the negative battery cable. MANUAL TO.5—3.4—3. FROM. Timing Belt Cover Installation Note. Injection Nozzle Installation Note D Install each injection nozzle onto the FIP.) 4. TIMING BELT. INJECTION NOZZLE FIP COLOR RING CONTINUED F2–18 .BACK. (Refer to FUEL SYSTEM. Complete the “BEFORE REPAIR PROCEDURE”. D Catch the fuel with a rag. 49 S120 215A 1 2 3 4 5 6 FIP PULLY LOCKNUT 25—29 {2.4 N·m {25—35 kgf·cm. matching their identification color rings as shown. 1. 3.CHAPTER. (Refer to FUEL SYSTEM.DRFT. 5. 6.INDEX RANG. 2. AFTER REPAIR PROCEDURE. 22—30 in·lbf} FIP Removal Note 1. Remove the two FIP pulley mounting bolts.) Corrugated Gasket Installation Note D Install the bead side facing combustion chamber. Install in the reverse order of removal. Remove the pulley with the SST. Remove in the order indicated in the table. FIP mounting bolt FIP mounting nut FIP + Removal Note Key 59—68 {6.INDEX FUEL SYSTEM 1 2 3 4 5 6 Injection pipe Accelerator cable Fuel hose Connector Vacuum hose Timing belt cover + Section B2.) 3. TIMING BELT REMOVAL/INSTALLATION. Remove the FICD solenoid valve bracket. (Refer to INTAKE-AIR SYSTEM.7—3.

2. foreign material may get stuck between the nozzle and the nozzle tester. INJECTION NOZZLE INSPECTION Caution D Fuel and fuel tank used for the nozzle tester must be kept clean.0—5. 2. Disassemble in the order indicated in the table. causing damage.CHAPTER. Otherwise. Note D Adding/subtracting 0. CONTINUED F2–19 . Slowly lower the nozzle tester handle and note the pressure when injection starts. N·m {kgf·m. Lower the handle several times as quickly as possible so that a pulsating whistling sound is heard. 1650—1760 psi} (New) More than 10.INDEX RANG. Bleed the air by pumping the nozzle tester handle several times. proper atomization (2) Incorrect injection angle and direction (1) (2) NORMAL FAULTY ANGLE FAULTY DIRECTION 4.INDEX FUEL SYSTEM INJECTION NOZZLE DISASSEMBLY/ASSEMBLY Caution D The injection port is very small so it must be kept clean. causing damage. 2.8 kgf/cm2. 3. disassemble and clean or replace the injection nozzle. 470 kPa {4.4—12. If the injection starting pressure is not within the specification.0 MPa {102 kgf/cm2.1 MPa {116—124 kgf/cm2. 22—36} 1 2 3 4 5 6 7 8 9 Nozzle holder body + Disassembly Note Ring Shim Nozzle spring Spring seat Spacer Needle valve + Assembly Note Nozzle body Retaining nut ADJUSTING SHIM Nozzle Holder Body Disassembly Note D Secure the retaining nut in a vise and remove the nozzle holder body. 3. Otherwise.0008 in} thickness shim increases/decreases the starting pressure approx. Injection starting pressure 11. Needle Valve Assembly Note D When the nozzle body or the needle valve is damaged.02 mm {0.REPAIR MANUAL PAGES.0. Connect the injection nozzle to a nozzle tester. FROM.DRFT. MODEL . foreign material may get stuck in the injection nozzle. Connect the injection nozzle to the nozzle tester. replace them as a set. and note the atomization pattern. Assemble in the reverse order of disassembly. (1) Uniform.TO. ft·lbf} 29—49 {3. 1. If necessary.BACK. Injection Starting Pressure 1. adjust it by installing the correct shim. 1450 psi} (Inspection) 4. MANUAL TO. Atomization 1. Bleed the air by pumping the nozzle tester handle several times. 68 psi}.

Verify that the FCV stem is drawn into the FCV. disconnect the FCV connector and verify that the engine stops. 2.DRFT. Verify that the needle valve moves smoothly in the nozzle body. 3. Hold the nozzle body upright and insert approximately two thirds of the needle valve. Install in the reverse order of removal. Connect the battery positive voltage to the FCV terminal and GND the FCV body. Off-vehicle Inspection 1. carry out the following inspection. 2. CORRECT WRONG 4. 5. disassemble and clean or replace the injection nozzle. 6.5—2.CHAPTER. 4. Verify that the needle valve and nozzle body are not damaged. Remove the FCV. (Refer to FUEL SYSTEM. Disconnect the negative battery cable. 2. If carbon is observed inside of the nozzle. NUT 2. 18—21 in·lbf} FCV 15—25 {1. Connect the injection nozzle to the nozzle tester.8 MPa {90 kgf/cm2. ft·lbf} NOZZLE BODY FUEL CUT VALVE (FCV) INSPECTION Without immobilizer system On-vehicle Inspection Note D Perform the following test only when directed. If the engine does not stop. If not. Remove the FCV. Verify that the nozzle body is not damaged. FROM. 7. MODEL .280 psi} pressure to the injection nozzle.INDEX RANG. remove it by using a toothpick. BEFORE REPAIR PROCEDURE. Remove the needle valve from the nozzle body. Injection Nozzle Cleaning 1. 1. 3. 4. and inspect for fuel leakage from the nozzle spray port. 3. Inspect the outer and inner surfaces of the injection nozzle for carbon accumulation.0—2. 1. then see if the needle valve drops to the valve seat by its own weight when released.INDEX FUEL SYSTEM Nozzle Leakage 1. replace the nozzle assembly.) 3. remove it by using a hard wood chip. If carbon is observed on the outer surface.6. If fuel leaks. NEEDLE VALVE FUEL CUT VALVE (FCV) REMOVAL/INSTALLATION Without immobilizer system 1.4 N·m {20—25 kgf·cm. Clean the needle valve and the nozzle body with clean light oil. Complete the “BEFORE REPAIR PROCEDURE”. With the engine idling. Disconnect the negative battery cable. Apply 8. 2. MANUAL TO.TO. 2. 2.BACK. Bleed the air by pumping the nozzle tester handle several times. 4. Operating Inspection 1.REPAIR MANUAL PAGES. CONTINUED F2–20 . 11—18} N·m {kgf·m.

No.2 INSPECTION System Inspection 1.1.INDEX RANG. inspect following: Vacuum hose improper routing. MODEL .1. 6.1 connector terminal B and PCM connector terminal C) D GND circuit (FICD solenoid valve No. 7. No. kinks or leakage.REPAIR MANUAL PAGES. Carry out the “FICD System Inspection”.1. Repair or replace faulty areas. If as specified but the “System Inspection” is failed. 7. perform the further inspection for the FICD solenoid valve No. 4. If not as specified. (Refer to TROUBLESHOOTING.BACK. If not as specified. Reconnect the negative battery cable.1 connector terminal B and PCM connector terminal IG1) D GND circuit (FICD solenoid valve No. replace the faulty FICD solenoid valve. 8.1 connector terminal A and engine switch connector terminal IG1 to GND) D Power circuit (FICD solenoid valve No.2 connector terminal A and engine switch connector terminal IG1) ENGINE SWITCH A B A B C D HARNESS SIDE CONNECTOR (VIEW FROM TERMINAL SIDE) Short circuit D GND circuit (FICD solenoid valve No.2. Replace the FCV if not as specified.2 connector terminal A and engine switch connector terminal IG1 to GND) 5. NO. Install the FICD solenoid valve No. Airflow Inspection Note D Perform the following test only when directed.2 connector terminal B and PCM connector terminal P) D Power circuit (FICD solenoid valve No. SYSTEM INSPECTION.INDEX FUEL SYSTEM : Continuity Step 1 2 B+ GND Terminal A B A Port B C : Airflow B GND A B+ B 5. Remove the FICD solenoid valve No.TO. 1. CONTINUED F2–21 .1.) 2. MANUAL TO. inspect following: Open circuit D GND circuit (FCV body and engine switch connector terminal IG1) D Power circuit (FCV connector terminal and engine switch connector terminal IG1) ENGINE SWITCH A B C 123456567 A AIR FILTER A B C D HARNESS SIDE CONNECTOR (VIEW FROM TERMINAL SIDE) Short circuit D GND circuit (FCV body and engine switch connector terminal IG1 to GND) D Power circuit (FCV connector terminal and engine switch connector terminal IG1 to GND) 6.2 connector terminal B and PCM connector terminal P) D Power circuit (FICD solenoid valve No. Repair or replace faulty areas.DRFT. Inspect for airflow between ports of the solenoid valve. (Refer to INTAKE-AIR SYSTEM. FROM. Install the FCV.2. No. INTAKE-AIR SYSTEM REMOVAL/INSTALLATION.CHAPTER. If as specified. FICD SOLENOID VALVE NO.2. FICD System Inspection. Reconnect the negative battery cable.1 connector terminal A and engine switch connector terminal IG1) D Power circuit (FICD solenoid valve No.) 3. Open circuit D GND circuit (FICD solenoid valve No. 2. Disconnect the negative battery cable.

Continuity Inspection Note D Perform the following test only when directed. Disconnect the negative battery cable.CHAPTER. FROM. SYSTEM INSPECTION. Reconnect the FIP connector. but PCM terminal voltage is out of specification.INDEX FUEL SYSTEM TIMER CONTROL VALVE (TCV) INSPECTION Europe and UK 1. Open circuit D Power circuit (FIP connector terminal D and PCM connector terminal H) Short circuit D FIP connector terminal D and PCM connector terminal H to GND 5. send TCV to a distributor for replacement. Carry out the “Timer Control Valve (TCV) Control Inspection”.DRFT. 1.REPAIR MANUAL PAGES. 2. If not as specified. FIP A B C D E F G H COMPONENT SIDE CONNECTOR (VIEW FROM TERMINAL SIDE) 4. CONTINUED F2–22 . Disconnect the FIP connector (8–pin terminal). inspect as follows and repair or replace as necessary. MODEL .TO. 6.) 2. MANUAL TO. Timer Control Valve (TCV) Control Inspection. perform the further inspection for the TCV. Repair or replace faulty areas.BACK. Verify that there is continuity between the FIP connector terminal D and TCV body. If the TCV is okay. (Refer to TROUBLESHOOTING. 3. If not as specified.INDEX RANG.

Remove in the order indicated in the table.DRFT.H.) EUROPE and UK N·m {kgf·m. they can badly burn. 2. Turn off the engine and wait until they are cool before removing the exhaust system. 1.REPAIR MANUAL PAGES. EXHAUST SYSTEM REMOVAL/INSTALLATION Warning D When the engine and exhaust system are hot. 4 5 6 Front pipe Exhaust manifold insulator Exhaust manifold L. If leakage is found. ft·lbf} 1 2 3 Tail pipe Main silencer D Middle pipe (Turkey and General (R. Install in the reverse order of removal.) D OC (Europe and UK) CONTINUED F2–23 .INDEX EXHAUST SYSTEM EXHAUST SYSTEM EXHAUST SYSTEM INSPECTION 1..H.BACK.H. MODEL .D. repair or replace as necessary.. Start the engine and inspect each exhaust system component for exhaust gas leakage. FROM. 3. L. Disconnect the negative battery cable.H.D. 2.D. MANUAL TO.INDEX RANG.D.CHAPTER. WL TURKEY and GENERAL (R.TO.

FROM.D.)) D OC (Europe and UK) 6 7 8 9 Joint pipe Turbocharger + Removal Note Oil pipe + Installation Note Exhaust manifold Front pipe Exhaust manifold insulator CONTINUED F2–24 . MANUAL TO. L..D.INDEX EXHAUST SYSTEM WL TURBO EUROPE and UK TURKEY and GENERAL (R.) N·m {kgf·m.H.INDEX RANG. ft·lbf} 1 2 3 4 5 Tail pipe Main silencer D Middle pipe (General (L.DRFT.CHAPTER.D.REPAIR MANUAL PAGES. MODEL .TO.BACK.H.H.

4—3. D Cover the intake. 18—26 ft·lbf} OIL PIPE A EMISSION SYSTEM ROLLOVER VALVE INSPECTION 1.INDEX EXHAUST SYSTEM. If not as specified. Remove the evaporative chamber.REPAIR MANUAL PAGES. FROM. MODEL . Blow from port A and verify that there is airflow. replace the rollover valve. WATER PIPE 3. MANUAL TO. exhaust and oil passages to prevent dirt or other objects from entering.CHAPTER. Remove the rollover valve. D Do not bend the wastegate actuator mounting or rod.6 kgf·m. A B 3.TO. Water pipe D Install the water pipe and tighten to the specified torque.) 2. FUEL TANK REMOVAL/INSTALLATION. A 4. (Refer to FUEL SYSTEM.BACK. (Refer to FUEL SYSTEM.DRFT.) 2. replace the evaporative chamber. EVAPORATIVE CHAMBER INSPECTION If equipped 1. Verify that there is no airflow. If not as specified. then install the oil pipe. FUEL TANK REMOVAL/INSTALLATION. Turn the valve over and blow from port A. CONTINUED F2–25 . EMISSION SYSTEM Oil Pipe Installation Note D Be sure to confirm that the turbocharger is installed correctly. Tightening torque 24—35 N·m {2. Turbocharger Removal Note D Do not drop the turbocharger. Blow from port A and verify that there is airflow from port B.INDEX RANG.

Inspect for airflow between 1 and 2 when vacuum is applied using a vacuum pump as shown in the figure. but PCM terminal voltage is out of specification. Disconnect the negative battery cable. 5.9—10.7 N·m {80—110 kgf·cm. : Continuity Step 1 2 B+ GND Terminal A B A Port B C 19—25 {1.5—95. 14—18} 3. MODEL . Repair or replace faulty areas. MANUAL TO.3— –7. 2. 1.9—2. EGR PIPE.4 in·lbf} 19—25 {1. Disconnect the negative battery cable. FROM.REPAIR MANUAL PAGES. Inspect for airflow between ports of the solenoid valve. inspect as follows and repair or replace as necessary.6.INDEX EMISSION SYSTEM EGR VALVE INSPECTION WL Turbo for Europe and UK Airflow Inspection Note D Perform the following test only when directed. replace the EGR valve. 2. EGR VALVE REMOVAL/INSTALLATION WL Turbo for Europe and UK 1. 4.9—2. Remove the EGR solenoid valve (Refer to INTAKE-AIR SYSTEM. Install in the reverse order of removal. replace the EGR solenoid valve.TO. –6. 3. 6. If not as specified. D Vacuum hose improper routing.4} Except above Airflow Yes No Short circuit D EGR solenoid valve connector terminal A and PCM connector terminal 1R. inHg}) Below –21. 2.6. 69. 25—29} N·m {kgf·m. If not as specified.CHAPTER.BACK.3 {–160— –190.5—4. EGR SOLENOID VALVE INSPECTION WL Turbo for Europe and UK Airflow Inspection Note D Perform the following test only when directed.INDEX RANG. 7. kinks or leakage.0. 14—18} 35—40 {3. If the EGR solenoid valve is okay. WL Turbo. 1. ft·lbf} : Airflow 1 2 EGR pipe EGR valve B GND A B+ B C 123456567 A AIR FILTER CONTINUED F2–26 . INTAKE-AIR SYSTEM REMOVAL/INSTALLATION.3—–25.) 3. Remove in the order indicated in the table. Remove the EGR valve. Open circuit D Power circuit (EGR solenoid valve connector terminal A and PCM connector terminal 1R) D GND circuit (EGR solenoid valve connector terminal B and body GND through common connector) EGR SOLENOID VALVE A B HARNESS SIDE CONNECTOR (VIEW FROM TERMINAL SIDE) Vacuum (kPa {mmHg. Install the EGR solenoid valve connector.DRFT.

MANUAL TO.DRFT.TO. FROM. MODEL .BACK.2 FICD solenoid valve No.REPAIR MANUAL PAGES.CHAPTER.1 EGR solenoid ECT sensor DLC valve*1 10 11 12 13 14 15 16 17 A/C relay TCV*2 Control lever position sensor*2 Glow plug NE sensor Idle switch*2 Starter Glow plug relay WL Turbo for Europe and UK Europe and UK CONTINUED F2–27 .INDEX CONTROL SYSTEM CONTROL SYSTEM COMPONENT PARTS WL TURBO WL TURBO 1 2 3 4 5 6 7 8 9 *1: *2: Glow indicator light Temperature control dial Engine switch PCM FICD solenoid valve No.INDEX RANG.

and PCM to determine the cause of trouble. output systems.TO. (Refer to POWERTRAIN CONTROL MODULE (PCM) REMOVAL/INSTALLATION.) Note D With the PCM connector connected. MODEL . 5. FRONT SIDE TRIM REMOVAL/INSTALLATION. 3.DRFT. Remove the PCM with the connector connected. Remove the driver’s side front side trim. 4. If the output voltage is not normal while each input voltage is normal.INDEX CONTROL SYSTEM POWERTRAIN CONTROL MODULE (PCM) REMOVAL/INSTALLATION 1. Install in the reverse order of removal. replace the PCM.) CONTINUED F2–28 . Disconnect the battery negative cable.BACK. Install the PCM. inspect the related device systems. (Refer to Section S. TRIM. 8.) 2. FRONT SIDE TRIM REMOVAL/INSTALLATION. FRONT SIDE TRIM REMOVAL/INSTALLATION. Install the driver’s side front side trim.CHAPTER. FROM. Measure the voltage of each PCM terminals by using a voltmeter. Otherwise. (Refer to POWERTRAIN CONTROL MODULE (PCM) REMOVAL/INSTALLATION.INDEX RANG. When they are normal.7 N·m {90—130 kgf·cm. 4. body ground the voltmeter negative (–) lead and measure the voltage at each PCM terminal by inserting the voltmeter positive (+) lead. (Refer to Section S. Remove in the order indicated in the table. 1. TRIM. 78—112 in·lbf} 1 2 3 PCM connector PCM installation nut PCM POWERTRAIN CONTROL MODULE (PCM) INSPECTION Caution D The PCM terminal voltages vary with change in measuring conditions and vehicle conditions. 2.REPAIR MANUAL PAGES. MANUAL TO.) 3.9—12. Always carry out a total inspection of the input systems. Remove the driver’s side front side trim. a wrong diagnosis will be made.) 6. (Refer to Section S. TRIM.

FROM. MODEL .0 H H*1 – Idle (Control lever open or close) – Idle switch Engine switch is on. 1 No.INDEX CONTROL SYSTEM Terminal Voltage (Reference) Europe and UK S T Terminal Q R O P M N K L I J G H E C F D A B Turkey and General (R. B C System ground FICD control D Inspect related harness. G Temperature control dial is at position other than off and fan switch is on. 5. Temperature control dial is off and fan switch is off. – Accelerator pedal is depressed. 0.DRFT.REPAIR MANUAL PAGES.0 Approx. After warm-up F Engine speed (Input) A/C (With A/C) NE sensor Engine switch is on.0 B+ Below 1. D Start Engine switch (Starter) ECT sensor Engine switch is on.L.TO. CONTROL SYSTEM.2 INSPECTION D Inspect related harness D Inspect related harness E ECT D Inspect engine coolant temperature sensor. valve No.CHAPTER.0 Below 1. MANUAL TO.05 B+ Action – D Inspect related harness. + Section U. CONTROL SYSTEM. Voltage (V) – Approx.D. . Accelerator pedal is released.1.8 Approx. + ECT SENSOR INSPECTION D Inspect related harness D Inspect NE sensor. D Inspect PCM. + Section U.D. HEATER CONTROL UNIT INSPECTION D Inspect fan switch. Idle Temperature control dial Engine switch is on. HEATER CONTROL UNIT INSPECTION D Inspect related harness – D Inspect idle switch.1. Below 1. ECT is 20°C {68°F}. 10 Approx.H.BACK. 0. 0 Approx.1 Approx. D Inspect related harness. + NE SENSOR INSPECTION D Inspect related harness D Inspect microswitch.0 Below 1. – B+ Below 1. While cranking Engine switch is on. FICD SOLENOID VALVE No No.) O M K I G E C A P N L J H F D B Signal – Constant voltage A A*1 Connected to – D Control lever position osition sensor D EGR valve position sensor Ground FICD solenoid valve No.0 *1: Europe and UK CONTINUED F2–29 .INDEX RANG. 5.H. D Inspect FICD solenoid ECT is above 20°C {68°F}.0 Below 1.1 Test condition – Engine switch ON OFF Idle Constant Idle ECT is below 20°C {68°F}. 3. + IDLE SWITCH INSPECTION D Inspect related harness.0 Approx. + FUEL SYSTEM.

0.TO.. For less than 10 minutes after starting engine. While cranking Voltage (V) B+ Action D Inspect related harness Below 1.D.H.5 sec. Idle Engine switch OFF tion sensor. D Inspect glow indicator B+ g light + Section T. FROM. D Inspect related harness. Over 4.0 – – – – – Europe and UK *2: Turkey and General (R. K Engine speed (Out(Out put) Power supply Instrument cluster Engine switch Engine switch is on. WARNING AND INDICATOR SYSTEM.2 Approx.5 seconds (25 °C {77 °F}) after turning engine switch on.CHAPTER.0 B+ B+ ECT is above 60°C {140°F}. Idle A/C is not operating A/C is operating M Glow indicator light g control Glow indicator light g Engine switch is off.1 D Inspect engine switch.BACK. Over 10 minutes after starting engine.INDEX CONTROL SYSTEM Terminal Signal Glow plug voltage I Connected to Glow plug Test condition ECT is below 60°C {140°F}. L. 4.H. Idle A/C is not operating A/C is operating N*2 *1: D Inspect engine switch.0 B+ Below 1. 2 seconds after turning engine switch on. MANUAL TO. D Inspect control lever posi- J Power supply Engine switch Engine switch OFF ON J*1 Control lever position (Detection) ( ) Control lever position sensor Engine switch is on. 2 seconds after turning engine switch on.REPAIR MANUAL PAGES. Below 1.INDEX RANG. While cranking For less than approx. For less than approx.0 Below 1. (25 °C {77 °F}).0 B+ Below 1.9—7. D Inspect A/C relay. Over approx.0 B+ B+ B+ Below 1. 15 seconds after turning engine switch on. + S Section ti U. L*1 Below 1. 15 seconds after turning engine switch on. U CONTROL SYSTEM. IGNITION SWITCH INSPECTION D Inspect related harness. Over approx. .DRFT.0 B+ Approx. . IGNITION SWITCH INSPECTION D Inspect related harness. Accelerator pedal is fully closed.5 B+ 6. POWER SYSTEM. + CONTROL LEVER POSITION SENSOR INSPECTION D Inspect related harness. D Inspect A/C relay. B+ B+ Below 1. MODEL . WARNING AND INDICATOR LIGHT BULB REPLACEMENT D Inspect related harness. A/C RELAY INSPECTION D Inspect related harness. + Section T.8—1.0 ON L*2 A/C control (With A/C) A/C relay Engine switch is on. N*1 A/C control (With A/C) A/C relay Engine switch is on.) CONTINUED F2–30 . U CONTROL SYSTEM.D. + Section T. Engine switch is on and within approx. A/C RELAY INSPECTION D Inspect related harness. Accelerator pedal is fully open. + S Section ti U. POWER SYSTEM. 4.

– D Inspect TCV.0 0—B+ – D Inspect related harness. While cranking Engine coolant temperature is above 60°C {140°F}. MODEL . 15 seconds after turning engine switch on.REPAIR MANUAL PAGES.0 – Engine switch is on on.2 Idle is not at OFF D Engine coolant temperature is below 60°C {140°F}. Test condition For less than approx. For less than 10 minutes after starting engine.BACK.DRFT. Q Q*1 – Timer control TCV – Engine switch is on. Over approx. + INTAKE-AIR SYSTEM. Over approx.) *3: WL Turbo for Europe and UK CONTINUED F2–31 .INDEX RANG. + FUEL SYSTEM.D. Idle – B+ Below 1.INDEX CONTROL SYSTEM Terminal Signal Glow system Connected to Glow plug relay Engine coolant temperature is below 60°C {140°F}. is not at OFF D Engine coolant temperature is above 60°C {140°F}. For less than approx. S S*1 – Diagnostic test mode – Data link connector (DLC) (Terminal TEN) – Data link connector (DLC) (Ter (Terminal FEN) T T*1 – DTC output *1: *2: Europe and UK Turkey and General (R. Idle – – B+ Below 1. R R*3 – EGR valve control – EGR solenoid valve – D Inspect EGR solenoid valve. TIMER CONTROL VALVE (TCV) INSPECTION D Inspect related harness.0 B+ Below 1.0 B+ Below 1. – D Inspect related harness.1. 2 seconds after turning engine switch on. L. While cranking D Temperature control dial Voltage (V) B+ Action D Inspect glow plug relay. + EMISSION SYSTEM.0 – Below 1.H. D Temperature control dial B+ valve No.H. 15 seconds after turning engine switch on. FICD SOLENOID VALVE No. FROM. + CONTROL SYSTEM. Over 10 minutes after starting engine.2..CHAPTER. GLOW PLUG RELAY INSPECTION D Inspect related harness.0 D Inspect FICD solenoid P FICD control FICD solenoid valve No.2 INSPECTION D Inspect related harness.TO. 2 seconds after turning engine switch on.0 B+ B+ Below 1. SYSTEM EGR SOLENOID VALVE INSPECTION D Inspect related harness. MANUAL TO. O Below 1.D.0 – Engine switch is on. Open terminal TEN Short terminal TEN – No DTC output DTC output – B+ Below 1. No.

(Refer to Section E. Refill the radiator with the specified engine coolant. MANUAL TO. but PCM terminal E voltage is out of specification. If not as specified.CHAPTER. 3. Disconnect the NE sensor connector.TO. 1. FROM. MODEL . replace the ECT sensor. ENGINE COOLANT REPLACEMENT. (Refer to Section E.BACK. inspect the following: Open circuit D Engine speed (input) circuit (NE sensor connector terminal A and PCM connector terminal F) D GND circuit (NE sensor connector terminal B and PCM connector terminal B) Short circuit D NE sensor connector terminal A and PCM connector terminal F to GND 5. 2. A B 5.INDEX RANG.9—10. If not as specified. Place the sensor in water with a thermometer. Remove the ECT sensor.7 N·m {80—110 kgf·cm.4 in·lbf} 4. 69.DRFT. ENGINE COOLANT TEMPERATURE (ECT) SENSOR INSPECTION Note D Perform the following test only when directed.29—0. If ECT sensor is okay. A B Specification 800—920 Ω 3.73 0. Disconnect the ECT sensor connector. 7. Reconnect the NE sensor connector. If NE sensor is okay. inspect as follows: CONTINUED F2–32 . but PCM terminal F voltage is out of specification.REPAIR MANUAL PAGES. 12—17 in·lbf} 9.27—2. ENGINE COOLANT.4 kgf·m. replace the NE sensor. Specification Water temperature (°C {°F}) 20 {68} 80 {176} Resistance (kΩ) 2.6—2. ENGINE COOLANT. Drain the engine coolant from the radiator. 1. Measure the resistance between engine coolant temperature sensor terminals A and B by using an ohmmeter. and heat the water gradually.34 6. Measure the resistance between the NE sensor connector terminals A and B by using an ohmmeter.5—95. Install the ECT sensor. Tightening torque 7.) 8. Repair or replace faulty areas. 6. 4.) 2. ENGINE COOLANT REPLACEMENT. Tightening torque 16—23 N·m {1.INDEX CONTROL SYSTEM NE SENSOR INSPECTION Note D Perform the following test only when directed.

replace the control lever position sensor.BACK. loosen the idle switch locknut and adjust the continuity by turning the idle switch. Verify that the FIP control lever is fully closed. 0. FROM. Repair or replace faulty areas. inspect as follows and repair or replace as necessary. 3. 2. MODEL . Accelerator pedal is fully closed. Be sure to disconnect the connector when turning the idle switch more than one rotation. Disconnect the negative battery cable. 4.5 Caution D Turning the idle switch with its connector connected can break the harness. 4. If not as specified. CONTROL LEVER POSITION SENSOR INSPECTION Europe and UK Output Voltage Inspection Note D Perform the following test only when directed. Voltage (V) Approx. When the reading is out of specification. If the PCM terminal voltage is out of specification. Turn the engine switch on and measure the PCM terminal J voltage. Open circuit D Power supply circuit (Idle switch connector terminal E and PCM connector terminal 2H through common connector) D GND circuit (Idle switch connector terminal and body GND) G H E F C D A B HARNESS SIDE CONNECTOR (VIEW FROM TERMINAL SIDE) Short circuit D Power supply circuit (Idle switch connector terminal E and PCM connector terminal H through common connector to GND) 6. replace the idle switch. Reconnect the 8-pin connector of FIP. inspect as follows and repair or replace as necessary.CHAPTER. Disconnect the 8-pin connector of FIP. If the idle switch is okay. 5. If not as specified. but PCM terminal voltage is out of specification.INDEX CONTROL SYSTEM Open circuit D Reference voltage circuit (ECT sensor connector terminal A and PCM connector terminal E through common connector) D GND circuit (ECT sensor connector terminal B and PCM connector terminal B through common connector) Short circuit D ECT sensor connector terminal A and PCM connector terminal E through common connector to GND 10. IDLE SWITCH INSPECTION Europe and UK Continuity Inspection Note D Perform the following test only when directed. 3. Inspect for continuity between the idle switch terminal E and ground using an ohmmeter. MANUAL TO. Specification A B C D E F G H COMPONENT SIDE CONNECTOR (VIEW FROM TERMINAL SIDE) Specification : Continuity Measuring g condition Not accelerated Other Terminal E GND Measuring condition Accelerator pedal is fully open.8—1. Reconnect the ECT sensor connector.TO.INDEX RANG. 7.REPAIR MANUAL PAGES. 1. send the FIP with the control lever position sensor to a distributor to repair. Repair or replace faulty areas. 1.DRFT. 11.2 Approx. 2. Open circuit D Constant voltage circuit (Control lever position sensor connector terminal B and PCM connector terminal A through common connector) D Control lever position signal circuit (Control lever position sensor connector terminal A and PCM connector terminal J through common connector) D GND circuit (Control lever position sensor connector terminal C and PCM connector terminal B through common connector) CONTINUED F2–33 . If not as specified.

Repair or replace faulty areas.INDEX RANG.REPAIR MANUAL PAGES. 5.BACK.INDEX CONTROL SYSTEM G H E F C D A B HARNESS SIDE CONNECTOR (VIEW FROM TERMINAL SIDE) Short circuit D Control lever position sensor connector terminal B and PCM connector terminal A through common connector to GND D Control lever position sensor connector terminal A and PCM connector terminal J through common connector to GND 4. MANUAL TO. MODEL .DRFT.CHAPTER. Reconnect the 8-pin connector of FIP. CONTINUED F2–34 . FROM.TO.

4. then indicates 0V. and the positive lead to the DLC terminal +B. Turn the engine switch on.INDEX RANG. FROM. Note D If the “88” does not flash. CONTINUED F2–35 .) 8. After repairs. 2. 3. inspect the harness between the PCM terminal and the DLC. (Refer to AFTER REPAIR PROCEDURE. Verify that the buzzer sounds for approximately 3 seconds and code “88” flashes for 5 seconds. and the test switch to SELF TEST. Reconnect the negative battery cable. keep the starter operated for 5-6 seconds. If the harness is normal.BACK. 5. Verify that the DTC is not detected. and depress the brake pedal. D If the “88” flashes and the buzzer sounds more than 20 seconds. 4. the codes are displayed in numerical order. inspect the appropriate areas and repair as necessary. Note D A DTC consists of four numbers. Read the DTCs indicated by the movement of the voltmeter’s needle. Warm up the engine to normal operating temperature.INDEX ON-BOARD DIAGNOSTIC SYSTEM ON-BOARD DIAGNOSTIC SYSTEM Europe and UK only DTC READING PROCEDURE Using the SST (Self-Diagnosis Checker) 1. 8. 2. (“1” is always shown on the left window.TO. 3. and the related harnesses and connectors. If any DTCs are indicated. Remove the voltmeter and the jumper wire. 6. 3. Caution D Connecting the wrong DLC terminals may possibly cause a malfunction.CHAPTER.) 9. Connect the negative battery lead of voltmeter (20V range) to the DLC terminal FEN. Perform the “DTC READING PROCEDURE” again. The voltmeter indicates the battery positive voltage for approximately 3 seconds. 6. erase all DTCs from the memory. the needle does not move. Carefully connect the specified terminals only. AFTER REPAIR PROCEDURE 1. Note D If the engine will not start. Turn the dial switch on the SST (system selector) to 1. 7. Set the select switch on the SST (self-diagnosis checker) to A. If DTC is not detected. Turn the engine switch off. DLC TEN +B GND 4. 49 B019 9A0 DLC Using the Voltmeter 1. 7. Connect the DLC located in the engine compartment terminal TEN and GND using a jumper wire. turn the engine switch on. “00” will then be indicated.REPAIR MANUAL PAGES. inspect the appropriate areas and repair as necessary. 5. disconnect the negative battery cable for at least 20 seconds. If any DTCs are indicated. Connect the SSTs to the DLC located in the engine compartment and GND the black (negative) lead to the body.DRFT. replace the PCM and inspect.) D When there are multiple malfunctions. MANUAL TO. erase all DTCs from the memory. If DTC is not detected. MODEL . (Refer to AFTER REPAIR PROCEDURE. Remove the SSTs. 49 H018 9A1A FEN 2. After completion of repairs. After completion of repairs. They are flashed one by one in the right window on the display. inspect +B terminal of the data link connector.

Is same code No. Is there any DTC present after performing “After Repair Procedure”? PCM (20 PIN) ECT SENSOR E J B A B ACTION Yes No Yes No Yes No Yes No Yes No Yes No Repair or replace connector. Inspect for open or short circuit in wiring harness. D ECT sensor malfunction D Open or short circuit in wiring from ECT sensor terminal A to PCM terminal E D Open or short circuit in wiring from ECT sensor terminal B to PCM terminal B INSPECTION Does ECT sensor or PCM connector have poor connection? Disconnect ECT sensor connector. then go to Step 6. ENGINE COOLANT TEMPERATURE (ECT) SENSOR INSPECTION Clear DTC from memory.BACK. Repair connectors and/or harnesses. MODEL . Go to Step 1. Intermittent poor connection in harnesses or connector.INDEX ON-BOARD DIAGNOSTIC SYSTEM DTC INSPECTION DTC Table DTC No. FROM. Is there 5 V at connector terminal A? Is there continuity between connector terminal A and PCM terminal E? Is ECT sensor okay? + CONTROL SYSTEM.TO.INDEX RANG. Replace ECT sensor. (PCM terminal B–ECT sensor terminal B) Go to next step. then go to next step.0 sec. then go to Step 6.REPAIR MANUAL PAGES. 09 Indicator Pattern Condition Engine coolant temperature (ECT) sensor malfunction Control lever position sensor malfunction 12 36 Glow plug relay malfunction DTC 09 DETECTION CONDITION POSSIBLE CAUSE STEP 1 2 ENGINE COOLANT TEMPERATURE (ECT) SENSOR MALFUNCTION Input value to PCM is excessively high or low for more than 2. Go to next step. Repair or replace wiring harness. MANUAL TO. Go to next step. Troubleshooting completed.DRFT. Go to applicable DTC inspection.CHAPTER. Turn engine switch on. 3 4 5 6 HARNESS SIDE CONNECTOR (VIEW FROM HARNESS SIDE) HARNESS SIDE CONNECTOR (VIEW FROM TERMINAL SIDE) CONTINUED F2–36 . present after performing “After Repair Procedure”? Clear DTC from memory. Go to next step. then go to Step 6.

0 sec.75 V when continued for 1. input voltage from control lever position sensor is below 0. MODEL .DRFT. then go to Step 7. D When idle switch is on.REPAIR MANUAL PAGES. Go to next step. Go to next step. FROM. then go to next step. present after performing “After Repair Procedure”? Clear DTC from memory. Is same code No. Troubleshooting completed. Go to Step 1. Replace control lever position sensor. then go to Step 7. Inspect for open or short circuit in wiring harness.INDEX ON-BOARD DIAGNOSTIC SYSTEM DTC 12 DETECTION CONDITION CONTROL LEVER POSITION SENSOR MALFUNCTION D Input voltage from control lever positIon sensor is below 0. IDLE SWITCH INSPECTION Clear DTC from memory.1 V or above 4.INDEX RANG. Go to next step. Replace idle switch. Intermittent poor connection in harness or connector. Repair or replace wiring harness.TO. Turn engine switch on. (PCM terminal A–control lever position sensor terminal B) Go to next step. CONTROL LEVER POSITION SENSOR 3 4 5 6 7 8 A B HARNESS SIDE CONNECTOR (VIEW FROM HARNESS SIDE) HARNESS SIDE CONNECTOR (VIEW FROM TERMINAL SIDE) CONTINUED F2–37 . then go to Step 7. MANUAL TO.39V. Repair or replace wiring harness.CHAPTER. Repair or replace wiring harness. Go to next step. Is there any DTC present after performing “After Repair Procedure”? PCM (20 PIN) A J B G H E F C D ACTION Yes No Yes No Yes No Yes No Yes No Yes No Yes No Yes No Repair or replace connectors. Repair connector and/or harness. Go to applicable DTC inspection. then go to Step 7. then go to Step 7.BACK.35V or above 1. D Control lever position sensor malfunction D Idle switch malfunction D Open circuit in wiring from control lever position sensor (FIP connector: 8pin) terminal C to PCM termi- POSSIBLE CAUSE nal B D Open or short circuit in wiring from control lever position sensor (FIP connector: 8pin) terminal A to PCM terminal J D Open or short circuit in wiring from control lever position sensor (FIP connector: 8pin) terminal B to PCM terminal A D Open or short circuit wiring from idle switch (FIP connector: 8pin) terminal E to PCM terminal H STEP 1 2 INSPECTION Does control lever position sensor connector or PCM connector have poor connection? Disconnect control lever position sensor connector. Is there 5 V at connector terminal B? Is there continuity between connector terminal A and PCM terminal J? Is there continuity between connector terminal C and PCM terminal B? Is there continuity between connector terminal E and PCM terminal H? Is idle switch okay? + CONTROL SYSTEM SYSTEM.

then go to next step. MANUAL TO. Go to next step.0 sec. Repair or replace wiring harness. Go to Step 1.INDEX ON-BOARD DIAGNOSTIC SYSTEM DTC 36 DETECTION CONDITION GLOW PLUG RELAY MALFUNCTION D When the glow plug relay is on. then go to Step 5. Repair or replace wiring harness. Repair connectors and/or harnesses.CHAPTER. Is there any DTC present after performing “After Repair Procedure”? PCM (20 PIN) 3 4 5 6 7 HARNESS SIDE CONNECTOR (VIEW FROM HARNESS SIDE) HARNESS SIDE CONNECTOR (VIEW FROM TERMINAL SIDE) CONTINUED F2–38 .TO. current voltage signal of the relay below 1. Go to next step. Is there continuity between connector terminal A and PCM terminal O? Is there continuity between connector terminal A (B) and PCM terminal I? Is there continuity between connector terminal B and body GND? Is there continuity between connector terminal A (R) and glow fuse? Is glow plug relay okay? + INTAKE-AIR INTAKE AIR SYSTEM. Troubleshooting completed.REPAIR MANUAL PAGES. Replace glow plug relay. Go to applicable DTC inspection. SYSTEM GLOW PLUG RELAY INSPECTION Clear DTC from memory. GLOW PLUG RELAY A A O I (WIRE COLOR: R) (WIRE COLOR: B) A B Does glow plug relay connector or PCM connector have poor connection? Remove glow plug relay. Go to next step.0 V is inputted to the PCM continuously for more than 1. Go to next step. FROM.0 sec.BACK.0 V is inputted to the PCM continuously for more than 1. MODEL . POSSIBLE CAUSE STEP 1 2 D D D D Glow plug relay malfunction Open or short circuit in wiring from PCM terminal O to glow plug relay terminal A (BR) Open or short circuit in wiring from PCM terminal I to glow plug relay terminal A (B) Open or short circuit in wiring from glow plug relay terminal A (R) to glow fuse INSPECTION ACTION Yes No Yes No Yes No Yes No Yes No Yes No Yes No Repair or replace connectors. Go to next step.DRFT.INDEX RANG. D When the glow plug relay is off. present after performing “After Repair Procedure”? Clear DTC from memory. Repair or replace wiring harness. Is same code No. signal of the relay current voltage above 4. Intermittent poor connection in harnesses or connectors.

Engine misses during acceleration or cruising. Momentary minor irregularity in engine output. Engine noise from under hood. Engine speed fluctuates during acceleration or cruising.TO. A/C compressor magnetic clutch does not disengage. Excessive black smoke is observed in exhaust gas. power down when climbing hills).CHAPTER. Engine does not reach normal operating temperature. Engine stops unexpectedly at beginning of acceleration during acceleration or while cruising. Fuel is in tank Battery is in normal condition. Vehicle bucks/jerks during acceleration. 1 2 3 4 5 TROUBLESHOOTING ITEMS Melts main or other fuse Will not crank Hard start/long crank/erratic start/erratic crank Engine stalls After start At idle Cranks normally but will not start TROUBLESHOOTING ITEM TABLE D Confirm trouble symptom by using the following diagnostic index. DESCRIPTION — Starter does not work. No. MODEL . Refer to “ENGINE STALLS” if this symptom appears after engine stall. or deceleration. A/C always on/A/C compressor runs continuously. cruising. Intermittent concerns CONTINUED F2–39 . FROM. Vibration from under hood or driveline.DRFT. Momentary pause at beginning of acceleration or during acceleration. D If a diagnostic trouble code is displayed. Starter cranks engine at normal speed but engine will not run. Idle speed is too slow and engine shakes excessively. Overheating Runs cold Engine runs at higher than normal temperature/overheats.REPAIR MANUAL PAGES. A/C compressor magnetic clutch does not engage when A/C is turned on.e. Engine runs after engine switch is turned off. 6 7 Slow return to idle/fast idle Engine runs rough/rolling idle 8 9 Runs on Engine stalls/quits Engine runs rough Misses Buck/jerk Hesitation/stumble Surges Acceleration/cruise Acceleration/cruise Acceleration/cruise Acceleration/cruise/ deceleration Acceleration Acceleration/cruise Acceleration/cruise 10 11 12 13 14 15 16 17 18 19 20 Lack/loss of power Poor fuel economy High oil consumption/leaks Cooling system concerns Cooling system concerns Excessive black smoke Engine noise Vibration concerns (engine) A/C does not work. MANUAL TO.INDEX RANG. Engine speed continues at fast idle after warm-up. Performance is poor under load (i. Starter cranks engine at normal speed but engine requires excessive cranking. Battery is in normal condition. Engine speed fluctuates between specified idle speed and lower speed and excessive engine shake. refer to section GI to understand the basic troubleshooting procedure. Oil consumption is excessive. proceed with inspection steps for the code. Engine takes more time than normal to return to idle speed.BACK. then go to appropriate troubleshooting chart. Engine stops unexpectedly at idle and/or after start. Symptom occurs randomly and is difficult to diagnose. Fuel economy is unsatisfactory.INDEX TROUBLESHOOTING TROUBLESHOOTING FOREWORD Before processing with the following troubleshooting.

DRFT. FROM.BACK.CHAPTER.INDEX SYMPTOM TROUBLESHOOTING: Symptom 1-Melts main or other fuse Symptom 2-Will not crank Symptom 3-Hard start/long crank/erratic start/erratic crank Symptom 4-Engine stalls-after start/at idle Symptom 5-Cranks normally but will not start Symptom 6-Slow return to idle/fast idle Symptom 7-Engine runs rough/rolling idle Symptom 8-Runs on Symptom 9-Engie stalls/quits-acceleration/cruise Engine runs rough – acceleration/cruise Misses-acceleration/cruise Buck/jerk – acceleration/cruise/deceleration Hesitation/stumble – acceleration Surges – acceleration/cruise F2-49-50 F2-51-52 F2-53 F2-54 F2-55 F2-55 F2-56 F2-56-58 F2-58 F2-58-59 F2-59-60 F2-60 F2-40 F2-41 F2-42-43 F2-43-44 F2-45-46 F2-46 F2-47-48 F2-49 Symptom 10-Lack/loss of power-acceleration/cruise Symptom 11-Poor fuel economy Symptom 12-High oil consumption/leaks Symptom 13-Cooling system concerns-overheating Symptom 14-Cooling system concerns-runs cold Symptom 15-Excessive black smoke Symptom 16-Engine noise Symptom 17-Vibration concerns (engine) Symptom 18-A/C does not work Symptom 19-A/C is always on/a/c compressor runs continuously Symptom 20-Intermittent concerns CONTINUED .REPAIR MANUAL PAGES. MODEL . MANUAL TO.TO.INDEX RANG.

2 D FCV HEAD (30 A) GLOW (60 A) ENGINE (15 A) CONTINUED F2–40 .REPAIR MANUAL PAGES. MANUAL TO.TO. MODEL .INDEX RANG.BACK.DRFT.INDEX TROUBLESHOOTING SYMPTOM TROUBLESHOOTING SYMPTOM 1 MELTS MAIN OR OTHER FUSE TROUBLESHOOTING HINTS Inspect the condition of the fuse.1 D FICD solenoid valve No. Shorted harness fuse Deterioration Repair shorted harness and replace fuse Replace fuse Damaged Fuse MAIN (100 A) Related Wiring Harness Main fuse D Engine switch D Generator D PCM Blower relay D Blower fan motor A/C relay D Refrigerant pressure switch HEAD fuse D Generator Glow plug relay D Glow plugs Engine fuse D PCM D FICD solenoid valve No. FROM.CHAPTER.

+ Section T. + Section H. Go to Step 6. Go to next step. MANUAL TO. IGNITION SWITCH INSPECTION. loose wire.REPAIR MANUAL PAGES. 2 3 4 Disconnect battery negative cable. D Open starter circuit between battery and starter through engine switch D Starter malfunction D Seized/hydrolocked engine.CHAPTER. FLYWHEEL INSPECTION Service as required. Is starting system okay? Yes No Repair or replace open circuit. flywheel INSPECTION Verify the following: D Battery condition D Battery connection D Fuses Are all items okay? Turn engine switch to START. POWER SYSTEM. Replace engine switch. bent or corroded terminals. + Section G. Inspect Ins ect for continuity on following circuits: D Engine switch connector terminal STA and starter terminal S D Battery positive cable and starter magnet switch terminal B.INDEX TROUBLESHOOTING SYMPTOM 2 DESCRIPTION POSSIBLE CAUSE STEP 1 WILL NOT CRANK Starter does not work. Inspect for electrical connections. Inspect the charging system. 5 Yes No Yes No Go to next step. Is clicking sound heard from starter? Do any other electrical accessories work? RESULTS Yes No Yes No Yes No Go to next step. Inspect for seized/hydrolocked engine. Is engine switch okay? Inspect starting system. flywheel.DRFT. Go to next step. Disconnect engine switch and starter connectors.BACK.INDEX RANG.TO. CHARGING SYSTEM Go to next step. STARTING SYSTEM. + Section G. FROM. MODEL . ACTION Service as necessary and repeat Step 1. CLUTCH. Are all circuits okay? Inspect engine switch. STARTER INSPECTION 6 CONTINUED F2–41 .

TO. D Damaged valve seat. Is injection timing okay? Yes No CONTINUED F2–42 . Go to next step. D D D D D D Poor fuel quality Starting system malfunction Air cleaner restriction Incorrect idle speed Engine overheating Glow system malfunction RESULTS Yes D D D D D D Fuel leakage Incorrect injection timing FIP malfunction Injection nozzle malfunction Low engine compression pressure Fuel line clogging ACTION STEP 1 INSPECTION Verify the following: D Fuel quality including water contamination D Loose bands on intake-air system y D Cracks on intake-air system parts D Air cleaner element restriction Are all items okay? Is engine overheating? Go to next step. MANUAL TO. damage. replace the timing belt. Inspect for the following: D Burnt valve D Worn piston. Repair or replace as necessary.CHAPTER. Inspect glow system operation. IDLE SPEED ADJUSTMENT Repair or replace as necessary. If timing belt is broken.DRFT.INDEX TROUBLESHOOTING SYMPTOM 3 DESCRIPTION POSSIBLE CAUSE HARD START/LONG CRANK/ERRATIC START/ERRATIC CRANK Starter cranks engine at normal speed but engine requires excessive cranking.BACK. Adjust idle speed. Go to next step. FROM. adjust injection timing. Go to next step. + ENGINE TUNE-UP. Go to next step. Battery is in normal condition. Inspect TCV (if equipped). piston ring. adjust timing belt. Is any fuel leakage found in fuel pipe? Measure engine compression. Go to next step. 2 Yes No Go to flowchart No. + SYSTEM INSPECTION. Glow System Inspection Replace any defective parts as necessary. or cracks Is timing belt okay? Yes No Yes No Yes No Yes No 9 Inspect injection timing. go to next step.13 for “COOLING SYSTEM CONCERNS OVERHEATING”. MODEL .INDEX RANG. If tension or timing of timing belt is incorrect. No Service as necessary and repeat Step 1. Go to next step. damaged or cracked. + TIMER CONTROL VALVE (TCV) INSPECTION If TCV is okay. Go to next step. Is compression okay? Inspect timing belt for the following: D Chipping of gear teeth D Low tension D Breakage. Go to Step 9. D Worn valve stem or valve guide. If quick start system is okay. Repair or replace as necessary. or cylinder D Damaged cylinder head gasket. + ENGINE TUNE-UP.REPAIR MANUAL PAGES. INJECTION TIMING ADJUSTMENT 3 Does engine start normally after warm-up? Yes No 4 Is idle speed correct? Yes No 5 6 7 8 Is there any restriction in exhaust system? Inspect for fuel leakage from fuel pipe.

DRFT. Go to next step. 4 5 Does engine run normally after warm-up? Inspect glow system operation. Yes No Yes No 6 Yes No If A/C is always on. Turn the fan switch on. No Service as necessary and repeat Step 2. REFRIGERANT SYSTEM SERVICE PROCEDURES. Go to next step for vehicles without immobilizer system. Faulty nozzle gasket: Replace nozzle gasket. Clogged nozzle or seized needle valve: Disassemble and clean or replace the injection nozzle. go to step.INDEX TROUBLESHOOTING STEP 10 INSPECTION Remove and inspect injection nozzle as follows: D Clogged nozzle D Incorrect valve opening pressure D Faulty nozzle gasket Is injection nozzle okay? RESULTS Yes ACTION Remove FIP.CHAPTER. go to symptom troubleshooting No.13 for “COOLING SYSTEM CONCERNS-OVERHEATING”. Go to next step. Is quick start system operation normal? Note: D If the following test cannot be performed due to engine stalls. inspect fuel line for clogging. next ste Connect the pressure gauge to A/C lines. MODEL .BACK. + SYSTEM INSPECTION. If FIP okay. D Cooling fan operation. CONTINUED F2–43 . Go to Step 6 Go to next step. inspect following: D Refrigerant charging amount.19 “A/C always ON/A/C compressor runs continuously”. Is pressure within specification? + section U. + SYSTEM INSPECTION. No Go to next step. REFRIGERANT PRESSURE CHECK. MANUAL TO.TO. system Does immobilizer indicator light flash and indicate? Go to “ON-BOARD DIAGNOSTIC FUNCTION” of immobilizer system. Glow System Inspection. Glow System Inspection Go to next step. FROM. Inspect FIP. 3 Yes No Go to flowchart No. D D D D D D D Poor fuel quality Starting system malfunction Air cleaner restriction Incorrect idle speed Engine overheating A/C system improper operation Glow system malfunction RESULTS Yes D D D D D D D Fuel leakage Fuel filter clogging Incorrect injection timing FIP malfunction Injection nozzle malfunction Low engine compression FICD malfunction ACTION STEP 1 INSPECTION Note: D The following test should be performed on vehicles with immobilizer system.REPAIR MANUAL PAGES. No SYMPTOM 4 DESCRIPTION POSSIBLE CAUSE ENGINE STALLS – AFTER START/AT IDLE Engine stops unexpectedly at idle and/or after start. Incorrect valve opening pressure: Adjust injection nozzle opening pressure. For other symptoms. 2 Verify the following: D Fuel quality including water contamination D Loose bands on intake-air system y D Cracks on intake-air system parts D Air cleaner element restriction Are all items okay? Is engine overheating? Yes Go to next step. Repair or replace any defective part according to glow system operation results.INDEX RANG.

Is compression okay? Inspect timing belt for the following: D Chipping of gear teeth D Low tension D Breakage. If FICD system is okay. No.BACK. Does engine start now? Yes No Yes No Yes No Yes 9 10 11 Inspect fuel leakage from fuel pipe.DRFT. go to next step.REPAIR MANUAL PAGES.INDEX RANG. Repair or replace as necessary. D Damaged valve seat D Worn valve seat or valve guide Repair or replace as necessary. replace timing belt. or cracks Is timing belt okay? No 12 Inspect injection timing.1. FICD SOLENOID VALVE No. ENGINE COOLANT TEMPERATURE SENSOR INSPECTION D Vacuum pump D Vacuum leakage around vacuum pump or fittings D FICD solenoid valves + FUEL SYSTEM.2 INSPECTION D FICD actuator D PCM terminal voltage. Is injection timing okay? Yes No 13 14 Inspect fuel filter for clogging. FROM. Adjust injection timing. INJECTION TIMING ADJUSTMENT Go to next step. Faulty nozzle gasket: Replace nozzle gasket. ACTION Inspect the following: D Engine coolant temperature sensor + CONTROL SYSTEM. Is fuel filter okay? Remove injection nozzle. Go to next step.1 connector terminal B and PCM connector terminal C D Open circuit between FICD solenoid No. go to next step. + ENGINE TUNE-UP. Crank the engine.2 connector terminal B and PCM connector terminal P Repair or replace any defective part as necessary. Go to next step. damage. Inspect and adjust idle speed. 8 Depress accelerator pedal slightly. adjust timing. Inspect injection nozzle for the following: D Clogged nozzle D Seized needle valve D Incorrect valve opening pressure D Faulty nozzle gasket Is injection nozzle okay? Is valve clearance correct? Yes No Yes No 15 Yes No CONTINUED F2–44 . Go to next step. damaged or cracked. Incorrect valve opening pressure: Adjust injection nozzle opening pressure. IDLE SPEED ADJUSTMENT If symptom still appears. MANUAL TO. Inspect FIP. FICD System Inspection Is FICD operation normal? RESULTS Yes No Go to next step. + ENGINE TUNE-UP. MODEL . piston ring. Is any fuel leakage found in fuel pipe? Measure engine compression. Go to Step 12.TO. Adjust valve clearance. J D Open circuit between FICD solenoid No. Go to next step. + SYSTEM INSPECTION.CHAPTER. Replace fuel filter cartridge. If tension or timing of timing belt is incorrect. Inspect for the following: D Burnt valve D Worn piston. Remove FIP. If timing belt is broken. Go to next step. Clogged nozzle or seized needle valve: Disassemble and clean or replace the injection nozzle. or cylinder D Damaged cylinder head gasket.INDEX TROUBLESHOOTING STEP 7 INSPECTION Inspect FICD system operation.

MODEL . damage. system Does immobilizer indicator light flash and indicate? No Go to next step. If tension or timing of timing belt is incorrect.BACK. Is FCV operation sound heard? Yes Go to next step. Inspect for the following: D Stuck FCV D Open circuit in FCV D Open wiring harness between engine switch and FCV. adjust timing. STEP 1 INSPECTION Note: D The following test should be performed on vehicles with immobilizer system. D Poor ground of FCV. Go to next step.TO. FROM. If timing belt is broken. D Damaged valve seat D Worn valve stem or valve guide Repair or replace as necessary. Go to next step for vehicles without immobilizer system. Adjust injection timing. replace timing belt. MANUAL TO. damaged or cracked. Battery is in normal condition. INJECTION TIMING ADJUSTMENT Go to next step. Is injection timing okay? Yes No Go to next step. No Service as necessary. Inspect for the following: D Burnt valve D Worn piston.CHAPTER. Fuel is in tank. Is fuel filter okay? Remove injection nozzle. Faulty nozzle gasket: Replace nozzle gasket. Replace fuel filter cartridge. + ENGINE TUNE-UP. Refer to “ENGINE STALLS” if this symptom appears after engine stall. Go to next step. Go to step 6. 7 8 Inspect fuel filter for clogging. piston ring or cylinder D Damaged cylinder head gasket.INDEX TROUBLESHOOTING SYMPTOM 5 DESCRIPTION CRANKS NORMALLY BUT WILL NOT START D D D D D D D D D POSSIBLE CAUSE Starter cranks engine at normal speed but engine will not run. Go to next step.REPAIR MANUAL PAGES. 3 Yes No 4 5 Measure engine compression. 2 Verify the following: D Fuel quality including water contamination D Loose bands on intake-air system D Cracks on intake-air system parts D Air cleaner element restriction D Fuses Are all items okay? Turn engine switch to ON. Clogged nozzle or seized needle valve: Disassemble and clean or replace the injection nozzle. Is compression okay? Inspect timing belt for the following: D Chipping of gear teeth D Low tension D Breakage. Poor fuel quality D Fuel filter clogged Air cleaner restriction D Incorrect injection timing FCV malfunction D FIP malfunction Low engine compression D Injection nozzle malfunction Fuel leakage RESULTS Yes ACTION Go to “ON-BOARD DIAGNOSTIC FUNCTION” of immobilizer system. Incorrect valve opening pressure: Adjust injection nozzle opening pressure.INDEX RANG. Repeat Step 2. or cracks Is timing belt okay? Yes No Yes No 6 Inspect injection timing. Inspect injection nozzle for the following: D Clogged nozzle D Seized needle valve D Incorrect valve opening pressure D Faulty nozzle gasket Is injection nozzle okay? Yes No Yes No CONTINUED F2–45 .DRFT.

Engine speed continues at fast idle after warm-up. ENGINE COOLANT TEMPERATURE (ECT) SENSOR INSPECTION D FICD solenoid valves + FUEL SYSTEM.TO. + section E. + ENGINE TUNE-UP. + SYSTEM INSPECTION. D PCM terminal voltage (J) + CONTROL SYSTEM. THERMOSTAT.1 connector terminal B and PCM connector terminal C. INJECTION TIMING ADJUSTMENT.CHAPTER.DRFT. MODEL . If FICD system is okay. Inspect FIP. PCM INSPECTION D Short to ground circuit between FICD solenoid valve No. D Short to ground circuit between FICD solenoid valve No.1. Is FICD operation normal? RESULTS Yes No Go to next step. D Malfunction of ECT sensor D Thermostat stuck open D FICD malfunction D Injection timing is incorrect. IDLE SPEED ADJUSTMENT Replace thermostat.2 INSPECTION D FICD actuators.BACK. Go to next step. D Accelerator cable free play incorrect adjustment D Idle speed incorrect adjustment INSPECTION Inspect FICD system operation. INJECTION TIMING ADJUSTMENT Inspect for free play of accelerator cable. No. inspect and adjust idle and/or idleup speed. If free play is okay. 2 Inspect injection timing. Is thermostat okay? Yes No 3 Yes No CONTINUED F2–46 . + ENGINE TUNE-UP.INDEX RANG. + ENGINE TUNE-UP.2 connector terminal B and PCM connector terminal P Repair or replace any defective part as necessary. SYMPTOM 6 DESCRIPTION POSSIBLE CAUSE STEP 1 SLOW RETURN TO IDLE/FAST IDLE Engine takes more time than normal to return to idle speed. THERMOSTAT INSPECTION. Adjust valve clearance.REPAIR MANUAL PAGES. FROM. FICD SOLENOID VALVE No. go to next step. MANUAL TO. Adjust free play as necessary. ACTION Inspect the following: D ECT sensor + CONTROL SYSTEM. Is injection timing okay? Remove thermostat and inspect operation. FICD System Inspection.INDEX TROUBLESHOOTING STEP 9 INSPECTION Is valve clearance correct? RESULTS Yes No ACTION Remove FIP. Adjust injection timing.

FROM. Glow System Inspection Go to next step. Go to flowchart No. Idle speed is too slow and engine shakes excessively. Go to Step 6. next ste Connect the pressure gauge to A/C (if equipped) lines. Repair or replace any defective part according to glow system operation results. go to symptom troubleshooting No. MANUAL TO. Inspect the following: D Engine coolant temperature sensor + CONTROL SYSTEM. Yes No If A/C is always on.13 for “COOLING SYSTEM CONCERNS-OVERHEATING”. Glow System Inspection. 2 3 4 Does engine run normally after warm-up? Inspect glow system operation. ECT SENSOR INSPECTION D Vacuum pump D Vacuum leaks around vacuum pump or fittings D FICD solenoid valves + FUEL SYSTEM. D D D D D D D POSSIBLE CAUSE Poor fuel quality Starting system malfunction Air cleaner restriction Incorrect idle speed Engine overheating A/C system improper operation Glow system malfunction RESULTS Yes No Yes No D D D D D D D Fuel leakage Fuel filter clogged Incorrect injection timing FIP malfunction Injection nozzle malfunction Low engine compression FICD malfunction ACTION STEP 1 INSPECTION Verify the following: D Fuel quality including water contamination D Air cleaner element restriction Is engine overheating? Go to next step.INDEX TROUBLESHOOTING SYMPTOM 7 DESCRIPTION ENGINE RUNS ROUGH/ROLLING IDLE Engine speed fluctuates between specified idle speed and lower speed and excessive engine shake. MODEL .BACK. go to step. If FICD system is okay.CHAPTER. go to next step.1 connector terminal B and PCM connector terminal C. For other symptoms. CONTINUED F2–47 . PCM INSPECTION D Open circuit between FICD solenoid valve No. 6 Inspect for FICD system operation. + SYSTEM INSPECTION INSPECTION. Service as necessary and repeat Step 1. Go to next step.INDEX RANG. REFRIGERANT PRESSURE CHECK. + SYSTEM INSPECTION. Is the pressure within specification? + section U. D Open circuit between FICD solenoid valve No.TO. + SYSTEM INSPECTION.DRFT.19 “A/C always ON/ A/C compressor runs continuously”.REPAIR MANUAL PAGES. Go to next step. Repair or replace any defective part as necessary. Go to Step 5. REFRIGERANT SYSTEM SERVICE PROCEDURES.2 connector terminal B and PCM connector terminal P. FICD SOLENOID VALVE No. Is glow system operation normal? Yes No Yes No 5 Note: D If the following test cannot be performed due to engine stalls.2 INSPECTION Inspection D FICD actuators D PCM terminal voltage (J) + CONTROL SYSTEM. inspect following: D Refrigerant charging amount. Turn the blower switch on. No. FICD System Inspection Is FICD operation normal? Yes No Go to next step.1. D Cooling fan operation.

REPAIR MANUAL PAGES. Does engine start now? RESULTS Yes ACTION Inspect and adjust idle speed. piston ring. Inspect TCV (if equipped). Carry out EGR system inspection. Replace fuel filter cartridge. INJECTION TIMING ADJUSTMENT Go to next step. + TIMER CONTROL VALVE (TCV) INSPECTION If TCV is okay. + ENGINE TUNE-UP. Is injection timing okay? Yes No 13 14 Inspect fuel filter for clogging. damage. Adjust valve clearance. Inspect injection nozzle for the following: D Clogged nozzle D Seized needle valve D Incorrect valve opening pressure D Faulty nozzle gasket Is injection nozzle okay? Is valve clearance correct? Yes No Yes No 15 Yes No CONTINUED F2–48 . EGR System Inspection Is EGR system okay? No Repair or replace as necessary. Go to next step. Go to next step. Remove fuel injection pump. No Yes No Yes 8 9 Inspect fuel leakage from fuel pipe. Go to next step. 10 11 Measure engine compression. No 12 Inspect injection timing. or cracks Is timing belt okay? Yes No Yes Go to Step12.BACK. Inspect follows: D Burnt valve D Worn piston. If timing belt is broken. Inspect fuel injection pump. Is fuel filter okay? Remove injection nozzle. Repair or replace as necessary. or cylinder D Damaged cylinder head gasket D Damaged valve seat D Worn valve stem or valve guide Repair or replace as necessary. Go to next step. + SYSTEM INSPECTION. replace timing belt. Incorrect valve opening pressure: Adjust fuel injection nozzle opening pressure. damaged or cracked. adjust injection timing. MANUAL TO.CHAPTER. Clogged nozzle or seized needle valve: Disassemble and clean or replace the fuel injection nozzle. Faulty nozzle gasket: Replace nozzle gasket. Go to next step.DRFT. If symptom still appears. go to next step. If tension or timing of timing belt is incorrect. Crank the engine.TO. Is compression okay? Inspect timing belt for the following: D Chipping of gear teeth D Low tension D Breakage.INDEX TROUBLESHOOTING STEP 7 INSPECTION Depress accelerator pedal slightly. + ENGINE TUNE-UP. Is any fuel leakage found on fuel pipe? Note: D The following test should be performed on vehicles with EGR system.INDEX RANG. Go to next step for vehicles without EGR system. MODEL . IDLE SPEED ADJUSTMENT. Go to next step. FROM. adjust timing belt.

REFRIGERANT PRESSURE CHECK.INDEX TROUBLESHOOTING SYMPTOM 8 DESCRIPTION POSSIBLE CAUSE STEP 1 RUNS ON Engine runs after engine switch is turned off. REFRIGERANT SYSTEM SERVICE PROCEDURES. Go to next step. Glow System Inspection Go to next step. Go to Step 5. Go to next step. No SYMPTOM 9 ENGINE STALLS/QUITS-ACCELERATION/CRUISE ENGINE RUNS ROUGH-ACCELERATION/CRUISE MISSES-ACCELERATION/ CRUISE BUCK/JERK-ACCELERATION/CRUISE/DECELERATION HESITATION/STUMBLE-ACCELERATION SURGES-ACCELERATION/CRUISE D Engine stops unexpectedly at beginning of acceleration. Inspect for FCV stuck to open. Inspect air cleaner for clogging.13 “COOLING SYSTEM CONCERNS OVERHEATING”. D FCV malfunction INSPECTION Run the engine at idle speed. Is air cleaner okay? Yes No Yes No 5 Yes No 6 Yes No CONTINUED F2–49 .INDEX RANG. inspect following: D Refrigerant charging amount. Engine speed fluctuates during acceleration or cruising. Is glow system operation normal? Connect the pressure gauge to A/C lines. Momentary pause at beginning of acceleration or during acceleration. Go to flowchart No. cruising. during acceleration or while cruisD D D D D DESCRIPTION ing. go to symptom troubleshooting No. Vehicle bucks/jerks during acceleration. MODEL .BACK. MANUAL TO. Does the engine stop? RESULTS Yes ACTION Inspect for the following: D Short to power line between engine switch and FCV. FROM. + SYSTEM INSPECTION. Momentary minor irregularity in engine output. Is the pressure within specifications? + section U. Engine misses during acceleration or cruising. Disconnect the FCV connector. If A/C is always on.CHAPTER. D D D D D D D POSSIBLE CAUSE D D D D D D D Glow system malfunction Fuel filter clogged Incorrect injection timing FIP malfunction Injection nozzle malfunction Low engine compression Clutch slippage ACTION STEP 1 INSPECTION Is idle speed stable? 2 Is engine overheating? Yes No 3 4 Does symptom disappear after warm-up? Inspect for glow system operation. Glow System Inspection. or deceleration. D Cooling fan operation. Go to flowchart No. Go to next step.TO. + SYSTEM INSPECTION. For other symptoms. Clean or replace air cleaner element. Verify that the engine stops.REPAIR MANUAL PAGES. Poor fuel quality Starting system malfunction Air leaks from intake-air system Air cleaner restriction Engine overheating A/C system improper operation Fuel leakage RESULTS Yes No Go to next step. Turn the blower switch on. Repair or replace wire harness. Go to next step. Repair or replace any defective part according to glow system operation results.DRFT.7 “ENGINE RUNS ROUGH/ROLLING IDLE”.19 “A/C ALWAYS ON/ A/C COMPRESSOR RUNS CONTINUOUSLY”.

Inspect follows: D Clutch slippage D FIP Adjust injection timing. damaged or cracked. Replace fuel filter cartridge. Is fuel filter okay? Measure engine compression. D Faulty nozzle gasket. complete the inspection. adjust timing belt. complete the inspection. or cylinder D Damaged cylinder head gasket D Damaged valve seat D Worn valve stem and valve guide Repair or replace as necessary.REPAIR MANUAL PAGES. Go to next step. If the concern is resolved. Is any fuel leakage found in fuel pipe? Inspect fuel filter for clogs. INJECTION TIMING ADJUSTMENT 9 Yes No 10 11 12 13 14 Yes No Yes No Yes No Yes No Yes No 15 Inspect injection timing. Inspect the hose band between the following parts: T b h i and d air i D Turbocharger compressor h housing cleaner D Turbocharger compressor housing and charge air cooler. Clogged nozzle or seized needle valve: Disassemble and clean or replace the injection nozzle. 8 Inspect for improper operation. WASTEGATE ACTUATOR INSPECTION. Is actuator okay? Remove injection nozzle. Go to Step 15. replace timing belt. Repair or replace as necessary. If the concern still exists. Go to next step. or disconnection on the wastegate actuator. MANUAL TO. For other models. Go to next step. Inspect injection nozzle for the following D Clogged nozzle. kinks. go to Step 9. If tension or timing of timing belt is incorrect. or cracks Is timing belt okay? Yes No Turbocharger is okay. Is compression okay? Inspect timing belt for the following: D Chipping of gear teeth D Low tension D Breakage. If timing belt is broken. FROM. piston ring. Incorrect valve opening pressure: Adjust injection nozzle opening pressure. Go to next step.INDEX TROUBLESHOOTING STEP 7 INSPECTION Note: D The following test should be performed on turbocharger equipped model. Inspect for the following: D Burnt valve D Worn piston. Go to next step. clogs. go to next step. If the concern is resolved. damage. Repair or replace as necessary.CHAPTER. + ENGINE TUNE-UP. Go to next step.INDEX RANG.TO. Go to next step. Is the hose band loose? RESULTS Yes ACTION Retighten the hose band. Is injection timing okay? Yes No CONTINUED F2–50 . Is injection nozzle okay? Is there any restriction in exhaust system? Inspect for fuel leakage from pipe. No Go to next step.DRFT. + INTAKE-AIR SYSTEM.BACK. Repair or replace as necessary. D Seized needle valve D Incorrect valve opening pressure. MODEL . the turbocharger is okay. Faulty nozzle gasket: Replace nozzle gasket. If the concern still exists.

Turn the fan switch on. Is the hose band loose? Yes No 4 5 Yes No Yes No Go to next step. 9 CONTINUED F2–51 . complete the inspection. If the concern still exists. Repair or replace as necessary.DRFT. Is there any problem? Turn the turbocharger compressor wheel by hand hand. go to Step 13. power down when climbing hills). Go to flowchart No.7 “ENGINE RUNS ROUGH/ROLLING IDLE”. Go to flowchart No. If A/C is always on. 8 Yes No Yes No Replace the turbocharger. For other symptoms. Go to next step.INDEX TROUBLESHOOTING SYMPTOM 10 DESCRIPTION POSSIBLE CAUSE LACK/LOSS OF POWER-ACCELERATION/CRUISE Performance is poor under load (i.BACK. go to symptom troubleshooting No. If the concern is resolved. go to next step. TURBOCHARGER INSPECTION.19 “A/C ALWAYS ON/ A/C COMPRESSOR RUNS CONTINUOUSLY”.CHAPTER. Does the wheel turn easily and smoothly? Yes No Go to next step. or interfering g with the housing on the vehicle. MANUAL TO. FROM. REFRIGERANT SYSTEM SERVICE PROCEDURES. Go to next step. . 13 “COOLING CONCERNS OVERHEATING”. Inspect if the turbocharger primary compressor wheel is bent. clogs.INDEX RANG. inspect the following: D Refrigerant charging amount. Replace the turbocharger. + INTAKE-AIR SYSTEM. + INTAKE-AIR SYSTEM. Is actuator okay? Remove the parts necessary to inspect the turbocharger.TO. Is the pressure within specification? + section U. Inspect air cleaner for clogging. Is air cleaner okay? Note: D The following test should be performed on turbocharger equipped model. D Cooling fan operation.REPAIR MANUAL PAGES. REFRIGERANT PRESSURE CHECK. 6 Inspect the wastegate actuator for improper operation. Inspect the hose band between the following parts: D Turbocharger T b h compressor h housing i and d air i cleaner D Turbocharger compressor housing and charge air cooler. Replace the turbocharger. or disconnection. the turbocharger is okay.e. Is there any problem? Inspect if the turbocharger compressor wheel locknut is loose or has fallen down inside turbocharger. Retighten the hose band. D D D D D D D D Poor fuel quality Starting system malfunction Air leaks from intake-air system Air cleaner restriction Engine overheating A/C system improper operation Clutch slippage Fuel leakage RESULTS Yes No D D D D D D D D Fuel filter clogged Incorrect injection timing FIP malfunction Injection nozzle malfunction Low engine compression pressure Turbocharger malfunction Brake system drags EGR system malfunction (WL Turbo) ACTION STEP 1 INSPECTION Is idle speed stable? Go to next step. MODEL . g . For other models. If the concern is resolved. Go to next step. complete the inspection. Do not remove the turbocharger. 7 Yes No Go to next step. 2 Is engine overheating? Yes No 3 Connect the pressure gauge to A/C lines. WASTEGATE ACTUATOR INSPECTION. kinks. damaged. Go to next step. Clean or replace air cleaner element. Go to next step. If the concern still exists. Go to next step.

Is there any problem? RESULTS Yes ACTION Replace the turbocharger. go to next step. Go to next step. replace timing belt. adjust timing. Inspect follows: D Brake system dragging D Clutch slippage D FIP Inspect TCV (if equipped). Install all removed parts in Step 7. Go to next step. The turbocharger is okay. Clogged nozzle or seized needle valve: Disassemble and clean or replace the injection nozzle. If timing belt is broken. 11 Is any engine oil found inside the turbocharger turbine housing? Yes If an excessive amount of oil is found on the vehicle. Go to next step. D Faulty nozzle gasket.TO. Inspect injection nozzle for the following: D Clogged nozzle. Go to next step. wipe the oil off the vehicle. D Seized needle valve D Incorrect valve opening pressure. No 12 Is any engine oil found inside the turbocharger compressor housing? Yes No 13 Remove injection nozzle. Is injection nozzle okay? Is there any restriction in exhaust system? Inspect fuel leakage from pipe.BACK.INDEX TROUBLESHOOTING STEP 10 INSPECTION Inspect if the turbocharger turbine wheel is damaged. EGR System Inspection Is EGR system okay? 18 19 Measure engine compression.INDEX RANG. Carry out EGR system inspection. go to next step. Go to next step. Is compression okay? Inspect timing belt for the following: D Chipping of gear teeth D Low tension D Breakage.DRFT. Note: D Inspect all fins on each turbine wheel. No Go to next step. Faulty nozzle gasket: Replace nozzle gasket. If tension or timing of timing belt is incorrect. or cylinder D Damaged cylinder head gasket D Damaged valve seat D Worn valve stem and valve guide Repair or replace as necessary. + TIMER CONTROL VALVE (TCV) INSPECTION If TCV is okay. Then. MANUAL TO. Inspect for the following: D Burnt valve D Worn piston. MODEL .CHAPTER. Go to next step. Yes No Yes Go to Step 20. adjust injection timing. Wipe the oil off the vehicle and install all removed parts in Step 7. + SYSTEM INSPECTION. Then. replace the turbocharger. or interfering with the housing on the vehicles. go to next step. FROM. Is any fuel leakage found on fuel pipe? Inspect fuel filter for clogging. Replace fuel filter cartridge. Repair or replace as necessary. INJECTION TIMING ADJUSTMENT No 20 Inspect injection timing. Repair or replace as necessary. Is injection timing okay? Yes No F2–52 CONTINUED . Incorrect valve opening pressure: Adjust injection nozzle opening pressure. damage. Is fuel filter okay? Note: D The following test should be performed on vehicles with EGR system. piston ring. Then. or cracks Is timing belt okay? Yes No 14 15 16 17 Yes No Yes No Yes No Yes No Repair or replace as necessary.REPAIR MANUAL PAGES. Go to next step for vehicles without EGR system. + ENGINE TUNE-UP. damaged or cracked. If a small amount of oil is found. Go to next step. cracked.

adjust timing belt . or cracks Is timing belt okay? Go to next step. damaged or cracked. Clogged nozzle or seized needle valve: Disassemble and clean or replace the injection nozzle. Incorrect valve opening pressure: Adjust injection nozzle opening pressure. Go to next step. Go to next step. Is compression okay? ? Inspect timing belt for the following: D Chipping of gear teeth D Low tension D Breakage. Is any f fuel leakage f found in f fuel pipe? ? Remove injection nozzle. Go to next step.CHAPTER. D Idle speed or idle-up speed incorrect adjustment D Accelerator cable free play incorrect adjustment D Air cleaner restriction D Engine cooling system malfunction D Improper transmission fluid level D Poor fuel quality D Improper coolant level D Improper engine compression INSPECTION RESULTS Yes D D D D D D D D D D Exhaust system clogged Injection timing incorrect Injection nozzle malfunction FIP malfunction High idle speed High idle-up speed FICD malfunction Fuel leakage Brake dragging EGR system malfunction (WL Turbo) ACTION STEP 1 2 Inspect the following: D Fuel quality including water contamination D Air cleaner element for restriction D Transmission fluid level D Coolant level Are all items okay? Inspect for idle speed and idle-up speed. D Faulty nozzle gasket. + ENGINE TUNE-UP. Go to next step. 8 9 Yes No Yes No Go to Step 10. If tension or timing of timing belt is incorrect. 3 4 5 6 7 Yes No Yes No Yes No Repair or replace as necessary. damage. FROM. No Service as necessary and repeat Step 1. Go to flowchart No.BACK. Inspect for the following: D FIP Adjust injection timing. MODEL . Faulty nozzle gasket: Replace nozzle gasket. or cylinder D Damaged cylinder head gasket D Damaged valve seat D Worn valve stem and valve guide Repair or replace as necessary. Yes No Yes No Yes No Go to next step. Carry out EGR system inspection.REPAIR MANUAL PAGES.TO. INJECTION TIMING ADJUSTMENT 10 Inspect injection timing. Inspect for the following: D Burnt valve D Worn piston.DRFT. Inspect for cause. piston ring. D Seized needle valve D Incorrect valve opening pressure.6 “SLOW RETURN TO IDLE/FAST IDLE”. Go to next step. Repair or replace as necessary. If timing belt is broken. Is injection timing okay? Yes No F2–53 CONTINUED . MANUAL TO.INDEX RANG.INDEX TROUBLESHOOTING SYMPTOM 11 DESCRIPTION POSSIBLE CAUSE POOR FUEL ECONOMY Fuel economy is unsatisfactory. Is injection nozzle okay? Is there restriction in exhaust system? Is brake system functioning properly? Note: D The following test should be performed on vehicles with EGR system. Inspect exhaust system. replace timing belt. + SYSTEM INSPECTION. Go to next step for vehicles without EGR system. EGR System Inspection Is EGR system okay? Measure engine compression. Is idle-up speed within specifications? Inspect fuel leakage from pipe. TUNE-UP IDLE-UP SPEED ADJUSTMENT. + ENGINE TUNE-UP. Go to next step. Inspect injection nozzle for the following: D Clogged nozzle.

MODEL . go to Step 10. D Worn or stuck piston ring. go to next step. Then. or interfering with the housing on the vehicles. Go to next step. Wipe the oil off the vehicle. 6 Is any engine oil found inside the turbocharger turbine housing? Yes If an excessive amount of oil is found on the vehicle. Go to next step. Replace the turbocharger. D Worn piston. Service as necessary. FROM. Inspect for the following: D Damaged valve seat.INDEX RANG. or interfering with the housing on the vehicle. go to next step. Install all parts removed in step 2. cracked.DRFT. replace the oil pipe. No 7 8 Is any engine oil found inside the turbocharger compressor housing? Is any engine oil found around oil pipes attached on the turbocharger center housing? Is any engine oil found inside the air intake pipes or Hoses? Measure engine compression. The turbocharger is okay.CHAPTER. Is there any problem? Yes No Yes No Yes Replace the turbocharger. Remove the parts necessary to inspect the turbocharger. Is there any problem? Turn the turbocharger compressor wheel by hand hand. If the oil leaked from the damaged pipe. or cylinder. Go to next step. D Worn valve stem and valve guide. Go to next step. 4 5 No Go to next step. 2 No Go to next step. For other models. Inspect oil leakage from outside of engine. 3 Inspect if the turbocharger compressor wheel locknut is loose or has fallen down inside turbocharger. Then. go to next step.INDEX TROUBLESHOOTING SYMPTOM 12 DESCRIPTION POSSIBLE CAUSE STEP 1 HIGH OIL CONSUMPTION/LEAKS Oil consumption is excessive. Replace the turbocharger. + INTAKE-AIR SYSTEM. Then. ACTION Service as necessary and repeat Step 1. Go to next step. Note: D Inspect all fins on each turbine wheel. D Improper engine oil level D Improper dipstick D Improper engine oil viscosity D Engine internal part malfunction D Oil leak D Turbocharger malfunction INSPECTION Inspect the following: D Proper dipstick D Pro Proper er engine viscosity D Engine oil level Are all items okay? Note: D The following test should be performed on turbocharger equipped model. damaged. Does the wheel turn easily and smoothly? Inspect if the turbocharger turbine wheel is damaged. Inspect if the turbocharger primary compressor wheel is bent.REPAIR MANUAL PAGES. wipe the oil off the vehicle. Do not remove the turbocharger. go to next step. replace the turbocharger. If a small amount of oil is found. Then. TURBOCHARGER INSPECTION Is there any problem? RESULTS Yes No Yes Go to next step. Wipe the engine oil off. MANUAL TO. Is compression okay? Yes No Yes No 9 Yes No Yes No 10 F2–54 CONTINUED . piston ring.BACK. Replace the turbocharger.TO.

Inspect thermostat.INDEX TROUBLESHOOTING SYMPTOM 13 DESCRIPTION POSSIBLE CAUSE COOLING SYSTEM CONCERNS—OVERHEATING Engine runs at higher than normal temperature/overheats. Is water temperature sender unit okay? No Service as necessary and repeat Step 1. No CONTINUED F2–55 . STEP 1 INSPECTION Inspect the following: D Engine coolant level D Coolant leakage D Radiator condition D Collapsed or restricted radiator hoses D Radiator pressure cap D Drive belt tension D Drive belt Are all items okay? Connect the pressure gauge to A/C lines. REFRIGERANT SYSTEM SERVICE PROCEDURES. THERMOSTAT INSPECTION Replace water temperature sender unit. 2 Yes No Go to next step.CHAPTER. D D D D D D D Cooling fan malfunction Low drive belt tension Drive belt damage Improper coolant level Thermostat malfunction Radiator clogging A/C system malfunction RESULTS Yes D Water temperature gauge or sender unit malfunc- tion D Improper or damaged radiator cap D Radiator hose damage D Coolant leakage (engine internal. 3 Yes No SYMPTOM 14 DESCRIPTION POSSIBLE CAUSE STEP 1 COOLING SYSTEM CONCERNS—RUNS COLD Engine does not reach normal operating temperature. MANUAL TO. + section T. MODEL .BACK. If A/C is always on. Inspect water temperature sender unit. WATER TEMPERATURE SENDER UNIT INSPECTION Replace thermostat.TO. For other symptoms.19 “A/C ALWAYS ON/ A/C COMPRESSOR RUNS CONTINUOUSLY”. go to symptom troubleshooting No. ex- ternal) ACTION Go to next step. FROM. THERMOSTAT INSPECTION INSPECTION.REPAIR MANUAL PAGES. + section E. THERMOSTAT. REFRIGERANT PRESSURE CHECK. THERMOSTAT. Is thermostat okay? RESULTS Yes ACTION Inspect water temperature sender unit operation.INDEX RANG. D Thermostat malfunction INSPECTION Remove the thermostat from vehicle. + section E.DRFT. Is the pressure within specification? + section U. INSTRUMENT CLUSTER. turbocharger. Turn the blower switch on. inspect the following: D Refrigerant charging amount D Cooling fan operation Inspect thermostat.

D Worn piston. Carry out EGR system inspection. Inspect TCV (if equipped).BACK. EGR System Inspection Is EGR system okay? Yes No 5 Yes No Repair or replace as necessary. D Worn or stuck piston ring. + ENGINE TUNE-UP. Repair or replace air cleaner element.TO. FROM. SYMPTOM 16 DESCRIPTION POSSIBLE CAUSE ENGINE NOISE Engine noise from under hood. MANUAL TO. Go to next step.INDEX TROUBLESHOOTING SYMPTOM 15 DESCRIPTION POSSIBLE CAUSE STEP 1 2 3 EXCESSIVE BLACK SMOKE Excessive black smoke is observed in exhaust gas. or cylinder. Is air cleaner element okay? Inspect injection timing.CHAPTER. + FUEL SYSTEM. D D D D Engine internal damage Timing belt displacement Injection nozzle malfunction Loose attaching bolts or worn parts D D D D Improper drive belt tension Air leaks from intake-air system Turbocharger operating noise EGR system malfunction (WL Turbo) CONTINUED F2–56 . Is compression okay? Yes No Inspect fuel injection pump. Clogged nozzle or seized needle valve: Disassemble and clean or replace the injection nozzle. Service as necessary. Go to next step. D Seized needle valve D Incorrect valve opening pressure D Faulty nozzle gasket Is injection nozzle okay? Note: D The following test should be performed on vehicles with EGR system. piston ring. Inspect for the following: D Damaged valve seat. 6 Measure engine compression. MODEL . Incorrect valve opening pressure: Adjust injection nozzle opening pressure. adjust injection timing. INJECTION TIMING ADJUSTMENT Go to next step. Go to next step. Inspect injection nozzle for the following: D Clogged nozzle.REPAIR MANUAL PAGES. D Air cleaner element restriction D Incorrect fuel injection timing D Injection nozzle malfunction D FIP malfunction D Low engine compression D EGR system malfunction (WL Turbo) INSPECTION Does any other symptom exist? Inspect air cleaner element for clogging.DRFT.INDEX RANG. Faulty nozzle gasket: Replace nozzle gasket. + SYSTEM INSPECTION. Go to next step for vehicles without EGR system. Go to next step. D Worn valve stem and valve guide. TIMER CONTROL VALVE (TCV) INSPECTION If TCV is okay. Is injection timing okay? RESULTS Yes No Yes No Yes No ACTION Go to appropriate flow chart. 4 Remove injection nozzle.

Inspect engine oil level or drive belt. MANUAL TO. Is there any problem? Turn the turbocharger compressor wheel by hand hand. Install all removed parts in Step1. Then.INDEX TROUBLESHOOTING STEP 1 INSPECTION Note: D The following test should be performed on turbocharger equipped model. Go to next step. 2 Inspect if the turbocharger compressor wheel locknut is loose or has fallen down inside the turbocharger. Inspect if the turbocharger compressor wheel is bent. cracked. Remove turbocharger. go to next step. wipe the oil off the vehicle. go to next step. Go to next step.BACK. If an excessive amount of oil is found on the vehicle. Does wheel turn easily and smoothly? Inspect if the turbocharger turbine wheel is damaged.TO. or chirp sound present? Is rumble or grind sound present? Is rattle sound present? Is hiss sound present? Yes No Yes No Yes No Yes 13 Is rap or roar sound present? No Yes No CONTINUED F2–57 . Is there any problem? Is any engine oil found inside the turbocharger turbine housing? Yes No Yes No Yes No Yes Replace the turbocharger. Go to next step. Inspect for cracks on center housing inlet surface. click. Go to next step. Wipe the oil off of the vehicle. If a small amount of oil is found. No Go to next step. attach the appropriate new bolt. Remove the necessary parts arts to inspect ins ect the turbocharger. Is there any problem? RESULTS Yes ACTION Replace the turbocharger. For other models. Go to next step. Inspect drive belt. Turbocharger is okay. Inspect for the following: D Vacuum leaks D Intake-air system leaks Go to next step. Go to next step. Then. replace the turbocharger. go to Step 9. Replace the turbocharger.REPAIR MANUAL PAGES. and nuts only. Replace the turbocharger. FROM. Then. Replace gaskets. MODEL . go to next step. DO NOT replace turbocharger. If any bolt is missing. Inspect exhaust system for loose parts. Go to next step. replace turbocharger.INDEX RANG. Go to next step. Inspect location of rattle for loose parts. Go to next step. If cracks are found. damaged. Go to next step.CHAPTER. or interfering with the housing on the vehicle. 3 4 5 6 7 Is any engine oil found inside the turbocharger compressor housing? Is any exhaust gas leakage found around the location where the turbocharger is attached to the exhaust manifold? No Yes No Yes 8 Are any of the attaching bolts of center housing and turbine housing loose? No Yes No 9 10 11 12 Is squeal. If no cracks are found. Go to next step.DRFT. or interfering with the housing on the vehicle. Retighten the loose bolts. bolts.

INDEX RANG. adjust injection timing. Seized A/C compressor Frost switch is stuck open. clogged nozzle or seized needle valve: Disassemble and clean or replace the injection nozzle. EGR System Inspection Is EGR system okay? Remove the fuel injection nozzle.BACK. + ENGINE TUNE-UP. No SYMPTOM 18 DESCRIPTION POSSIBLE CAUSE A/C DOES NOT WORK. D Loose attaching bolts or worn parts D Components malfunctions such as worn parts INSPECTION Inspect the following components for loose attaching bolts or worn parts: D Cooling fan D Drive belt and pulley D Engine mounts D Exhaust system Are all items okay? RESULTS Yes ACTION Inspect the following: D Wheels D Transmission and mounts D Driveline D Suspension Service as necessary. SYMPTOM 17 DESCRIPTION POSSIBLE CAUSE STEP 1 VIBRATION COCNERNS (ENGINE) Vibration from under hood or driveline. + SYSTEM INSPECTION. Carry out EGR system inspection.CHAPTER. Go to next step for vehicles without EGR system. D Improper refrigerant charging D D D D D D D D D D D D amount Microswitch is stuck open. 16 Yes No Inspect for the following: D Metal flow D Bent connecting rod D Damaged valve seat After-leakege.INDEX TROUBLESHOOTING STEP 14 INSPECTION Inspect the injection timing. MANUAL TO. Open A/C magnetic clutch Open circuit in related wire harnesses Poor ground of A/C magnetic clutch A/C low/high pressure switch is stuck open. A/C compressor magnetic clutch does not engage when A/C is turned on. Faulty nozzle gasket: Replace nozzle gasket. Service as necessary for other parts. 15 Note: D The following test should be performed on vehicles with EGR system. MODEL .TO. Inspect TCV (if equipped) + FUEL SYSTEM. Inspect for the following: D Clogged nozzle.REPAIR MANUAL PAGES.DRFT. Incorrect valve opening pressure: Adjust injection nozzle opening pressure. Open circuit in blower resistor Poor blower switch ground ECT sensor malfunction Improper magnet clutch clearance CONTINUED F2–58 . A/C relay is stuck open. D Seized needle valve D Incorrect valve opening pressure D Faulty nozzle gasket D Fuel dripping (fuel leakage) Is injection nozzle okay? Yes No Repair or replace as necessary. INJECTION TIMING ADJUSTMENT Go to next step. Is injection timing okay? RESULTS Yes No ACTION Go to next step. FROM. TIMER CONTROL VALVE (TCV) INSPECTION If TCV is okay. Readjust or retighten engine mount installation position.

PCM INSPECTION Specification: Less than 2. D Improper magnetic clutch clearD Short to power line between A/C relay and pressure ance D Short to ground circuit between PCM and frost switch D Short to ground circuit between PCM and A/C relay switch D A/C low/high pressure switch is stuck to close. A/C compressor magnetic clutch does not disengage. D Frost switch is stuck to close. 2 Turn the engine switch on. Set the fan switch to 1st position. D Open circuit between frost switch connector terminal and fan switch connector terminal. D Open circuit between blower motor and resistor D Open circuit between fan switch and resistor Repair or replace as necessary. Specification: More than 10.5 V Is voltage okay? Yes No SYMPTOM 19 DESCRIPTION POSSIBLE CAUSE A/C ALWAYS ON / A/C COMPRESSOR RUNS CONTINUOUSLY.CHAPTER. Measure the voltage at PCM connector terminal G. Inspect for the following: D Poor ground of A/C magnetic is clutch D Open circuit in magnet is clutch coil D Refrigerant charging amount Repair or replace as necessary.7 V Is voltage correct? Start the engine and run it at idle speed. FROM. Set the fan switch to 1st. CONTINUED F2–59 . MODEL .INDEX TROUBLESHOOTING STEP 1 INSPECTION Turn engine switch on. MANUAL TO. Specification: More than 10. + CONTROL SYSTEM. 2nd. Repair or replace as necessary. 3rd. Inspect for the following: D Frost switch is stuck open. D Magnetic clutch clearance D A/C compressor is seized.5 V Is voltage correct? Yes No 3 Yes No 4 Disconnect the A/C magnetic clutch connector. Inspect for the following: D Open circuit between pressure switch connector terminal and A/C magnetic clutch connector terminal D Refrigerant charging amount D A/C pressure switch is stuck open. Go to next step. 2nd.DRFT. Inspect for the following: D Open circuit in A/C relay coil D Poor contact in A/C relay D A/C relay stuck open D Open circuit between PCM connector terminal L and A/C relay connector terminal. or 4th position. Verify the blower motor is operating.INDEX RANG. Measure the A/C magnetic clutch connector terminal voltage.REPAIR MANUAL PAGES. Is blower motor okay? RESULTS Yes No Go to next step. D A/C relay is stuck to close. Go to next step. or 4th position. D Open circuit in battery supply line D Open circuit between engine switch and A/C relay connector terminal D Engine coolant temperature sensor malfunction Repair or replace as necessary. 3rd.BACK. D Poor contact of microswitch in heater control unit D Open circuit between PCM connector terminal G and frost switch connector terminal. Repair or replace as necessary.TO. Set the fan switch to 1st. D Open circuit in blower relay coil D Seized blower motor D Open circuit in blower motor coil. Measure the voltage at terminal of A/C relay connector terminal C. ACTION Inspect for the following: D Poor ground of fan switch D Open circuit in blower resistor D Poor contact of fan switch D Blower relay is stuck open.

Specification: 0V Is voltage correct? RESULTS Yes No Go to next step.BACK. Inspect wire and connector at suspect component for corrosion. MODEL . bent or loose terminal clamps. Adjust it as necessary. wiggle and pull each wire/connector at suspect component or PCM PCM. Retrieve vehicle service history. Measure the voltage at terminal of A/C relay connector terminal C. Go to next step. If fault occurred while spraying vacuum line: Repair vacuum hoses.7 V Is voltage correct? Start the engine and run it at idle speed. Go to symptom index. No Yes 4 No CONTINUED F2–60 . Turn the blower switch off. Fault area is identified. bent. Turn engine switch off.CHAPTER. Is any voltage out of range. D Short to power line between A/C relay connector terminal C and A/C pressure switch D Short to power line between pressure switch and A/C compressor magnetic is clutch connector Repair or replace as necessary. Turn the blower switch off. component. If input is switch-type component.REPAIR MANUAL PAGES.DRFT. bent or loose terminal clamps. FROM. wiggle and pull each wire/connector at suspect component or PCM. loose terminals. INSPECTION RESULTS Yes No Yes Go to next step. or poor wire terminal crimps and high tension wire. Are any voltages out of range. loose terminals. If fault occurred while spraying water: Inspect each wire for corrosion. Specification: More than 2. Inspect for magnetic is clutch clearance. Repair as necessary.INDEX TROUBLESHOOTING STEP 1 INSPECTION Turn the engine switch on. MANUAL TO. Lightly ta tap on sus suspect ect com component onent. ACTION Talk to customer. If fault occurred while spraying on component: Replace part and verify repair. Is any voltage out of range. ACTION Inspect for the following: D Short to ground circuit between PCM connector terminal G and frost switch D Short to ground circuit between frost switch and blower switch connector terminal Repair or replace as necessary. or suddenly change and go back into range. or do they suddenly change and go back into range? Accurately spray water on suspect component wire. Does vehicle have a number of previous revious repairs and components replaced for a certain symptom? Key off.INDEX RANG. Measure the voltage at PCM connector terminal G.TO. or vacuum line related to possible fault area. 3 Yes Inspect each wire for corrosion. Connect the voltmeter to the PCM terminals. or was there a noticeable engine stumble? 2 No Go to next step. turn on manually. bent. or do they suddenly change and go back into range? Start the engine and run it at idle speed. Inspect each wire for corrosion. Lightly tap on suspect component. Inspect for the following: D Short to ground circuit between PCM connector terminal L and A/C relay terminal C D A/C relay is stuck to close. or poor wire terminal clamps. 2 Yes No SYMPTOM 20 DESCRIPTION STEP 1 INTERMITTENT CONCERNS Symptom occurs randomly and is difficult to diagnose.

CONTINUED F2–61 . D Wiring harness between FICD solenoid valve No.) D Wire harness between FICD solenoid valve No. 13. disconnect vacuum hose B from the FICD actuator and inspect if there is vacuum. inspect the following. Disassembling the FIP without special tools and testers will cause a malfunction. 12. Verify that the FICD actuator rod is not pulled. Turn fan switch off. If there is no vacuum.) D Wiring harness between FICD solenoid valve No. Disassembling the FIP without special tools and testers will cause a malfunction. Warm up the engine (ECT is above 60 °C {140 °F}).INDEX RANG.TO. If there is vacuum. D FICD solenoid valve No.DRFT. 15. 4. (ECT above 20 °C {68 °F}).2. consult your distributor for replacement of the FICD actuator. inspect the following.INDEX TROUBLESHOOTING SYSTEM INSPECTION FICD System Inspection Fast-Idle Function 1. If not. VACUUM HOSE A 6. Warm up the engine. 7. E voltages (Refer to CONTROL SYSTEM.1 and PCM terminal C 14. 5. 3. Verify that the FICD actuator rod returns completely. If not. POWERTRAIN CONTROL MODULE (PCM) INSPECTION. Verify that the FICD actuator rod returns for one notch. Verify that the FICD actuator rod is pulled. FICD solenoid valve No. E and P voltages (Refer to CONTROL SYSTEM. If there is no vacuum. D PCM terminal C. disconnect the vacuum hoses from the FICD actuator and inspect if there is vacuum as shown. Special tools and testers are required when disassembling the FIP.REPAIR MANUAL PAGES. 16. If not.2 and PCM terminal P. Verify that the engine is cold (ECT is below 20 °C {68 °F}). 11. FROM. Caution D FIP is sealed to maintain proper function. disconnect vacuum hose A from the FICD actuator and inspect if there is vacuum. 2.1 and No. D FICD solenoid valve No.1 and PCM terminal C. Special tools and testers are required when disassembling the FIP.2 D Loose or damaged vacuum hoses between FICD actuator. MODEL . and vacuum pump.BACK.CHAPTER. 9. FICD ACTUATOR Caution D FIP is sealed to maintain proper function.1 and No. MANUAL TO.1 D PCM terminal C. Start the engine. POWERTRAIN CONTROL MODULE (PCM) INSPECTION. If there is vacuum. 8. consult your distributor for replacement of the FICD actuator. 10.

A/C Idle-up Function 1. Disconnect the air hose between the intake pipe and the boost compensator. BOOST COMPENSATOR PRESSURE GAUGE TO INTAKE PIPE 3. If there is vacuum. (Refer to INTAKE-AIR SYSTEM.0—73.) 7. inspect the wastegate actuator. If not as specified.82—10. 6.CHAPTER.2 D PCM terminal G and P voltages (Refer to CONTROL SYSTEM. Crank the engine and verify that the TCV operation sound is heard.) 6.INDEX RANG. 3. inspect the turbocharger. Set the fan switch at 1st position. inspect the exhaust system. 18.) D Wiring harness between FICD solenoid valve No.62—0. Connect a pressure gauge (range of measurement is 93. inspect the following: VACUUM HOSE B D FICD solenoid valve No. If there is no vacuum. If not.2 and PCM terminal P. With the accelerator at the wide open throttle.3 kPa {0.DRFT. 2. If the wastegate actuator is normal. TURBOCHARGER INSPECTION. increase the engine speed to 4800—5000 rpm and verify that the boost pressure is within the specification. consult your distributor for replacement of the FICD actuator. Warm up the engine. Verify that the FICD rod is pulled for one notch. consult your distributor for replacement of the FICD actuator. 17. disconnect the vacuum hose B from the FICD actuator and inspect if there is vacuum as shown.6 inHg}).INDEX TROUBLESHOOTING 7. 2. Start the engine.BACK. Disassembling the FIP without special tools and testers will cause a malfunction.POWERTRAIN CONTROL MODULE (PCM) INSPECTION) D Wiring harness between FICD solenoid valve No. MODEL . (Refer to EXHAUST SYSTEM. 5. 4.3 kPa {700 mmHg. WL VACUUM HOSE B Caution D FIP is sealed to maintain proper function.2 connector terminal B and PCM terminal P Turbocharger Boost Pressure 1. Disassembling the FIP without special tools and testers will cause a malfunction.REPAIR MANUAL PAGES. Special tools and testers are required when disassembling the FIP. G and P voltages (Refer to CONTROL SYSTEM. FROM. Specification 60.2 D PCM terminal E. Caution D FIP is sealed to maintain proper function.52 psi} 5. Wastegate Actuator Inspection. EXHAUST SYSTEM INSPECTION.TO. MANUAL TO.74 kgf/cm2. inspect the following. (Refer to INTAKE-AIR SYSTEM.) TCV Control Inspection (Europe and UK) 1. Warm up the engine to normal operating temperature and run it at idle speed. If there is no vacuum. 27. POWERTRAIN CONTROL MODULE (PCM) INSPECTION. TURBOCHARGER INSPECTION. TCV CONTINUED F2–62 . Special tools and testers are required when disassembling the FIP. D FICD solenoid valve No. 4. If there is vacuum. If the exhaust system is normal. 8.

) D Wire harness between EGR solenoid valve and PCM terminal R 6. Disconnect the vacuum hose from the EGR valve. inspect the following: D PCM terminal Q voltage (Refer to CONTROL SYSTEM. Verify that there is no vacuum at vacuum hose. inspect the following: D EGR solenoid valve D PCM terminal R voltage (Refer to CONTROL SYSTEM. CONTINUED F2–63 . 3. 8. 3. 11.INDEX RANG.) D Wire harness between EGR solenoid valve and PCM terminal R 9. 7. FROM. If there is no vacuum. Start the engine at cold condition. POWERTRAIN CONTROL MODULE (PCM) INSPECTION. If there is vacuum. Make sure that all hoses are securely connected in the proper position. Verify that there is vacuum at vacuum hose. stop the engine and inspect the EGR valve. 4. 2.REPAIR MANUAL PAGES.INDEX TROUBLESHOOTING WL Turbo TCV 2.BACK. Connect the vacuum pump to the EGR valve. Warm up the engine to the normal operating temperature and run it at idle speed. 10. If the engine speed does not change.TO.DRFT. POWERTRAIN CONTROL MODULE (PCM) INSPECTION. MANUAL TO. 5.CHAPTER. inspect the following: D EGR solenoid valve D PCM terminal R voltage (Refer to CONTROL SYSTEM. If no operation sound is heard. MODEL . inspect the TCV (in the FIP). Apply the vacuum to the EGR valve and inspect if the engine speed becomes unstable or the engine stalls. If the TCV is normal. POWERTRAIN CONTROL MODULE (PCM) INSPECTION) D Wire harness between TCV and PCM terminal Q EGR System Inspection (if equipped) 1.

After repair is completed. Illuminates for approx. Glow system is okay. Inspect for open or short circuit in harnesses and connectors between battery. and glow plug.? RESULTS Yes ACTION Go the appropriate DTC test. MANUAL TO. Measure resistance between glow plug and body ground. 1—9 seconds. 1 Ω or less? + INTAKE-AIR SYSTEM. FROM. 1 second (same condition after engine is warmed up and cold) D Extremely low resistance of engine coolant temperature sensor D Short circuit between engine coolant temperature sensor and PCM connector terminal E 3. GLOW PLUG INSPECTION Yes No 6 Yes No Replace glow plug. yg Is glow plug resistance approx. Go to next step. Inspect for open or short circuit in harnesses and connectors between NE sensor and PCM connector terminal F. Inspect glow plug relay ground circuit. Inspect the following according to indication condition of glow indicator light: 1. No Yes No 2 3 Leave engine switch on while engine is cold.INDEX RANG. Inspect for open circuit between glow relay and PCM terminal O.CHAPTER. Go to next step.INDEX TROUBLESHOOTING Glow System Inspection STEP 1 INSPECTION Connect NGS tester to DTC.DRFT.BACK. Will not illuminate D Glow indicator light D Open circuit between glow indicator light and PCM connector terminal M D Open circuit in instrument cluster print plate 4. Will not go out D Short circuit between glow indicator light and PCM connector terminal M D Short circuit in instrument cluster print plate 2. Are any of the following DTCs displayed? D 09 (ECT sensor) D 12 (Control lever position sensor) D 36 (Glow plug relay) Turn engine switch on while engine is cold. Does glow indicator light illuminate for approx. Inspect for open or short to ground circuit in harness and connectors between engine switch (starter) and PCM connector terminal D.TO. Go to next step. CONTINUED F2–64 .REPAIR MANUAL PAGES. 9 seconds (same condition after engine is warmed up and cold) D Extremely high resistance of engine coolant temperature sensor D Open circuit between engine coolant temperature sensor and PCM connector terminal E Go to next step. go to next step.? Yes No 4 Does glow plug voltage indicate B+ while cranking engine? Yes No 5 Is power supplied to the glow plug for maximum 10 minutes after engine started when engine is cold? Remove the glow plug wire from glow plugs. glow plug relay. Turn engine switch on and retrieve DTC. MODEL . 15 seconds. Does glow plug voltage indicate B+ for approx. Illuminates for approx. Inspect if glow plug relay is stuck open or closed. Go to next step.

..... F4-25 EMISSION SYSTEM ...................................................................................F4-14/15 FUEL LINE PRESSURE INSPECTION .......................................................F4-15/16 FAST IDLE SPEED ADJUSTMENT .... F4-27 FLANGE THERMOSWITCH INSPECTION ................................. F4-28 PCM REMOVAL/INSTALLATION ...................................... F4-18/21 CARBURETOR INSPECTION/ADJUSTMENT .........................F4-2 IDLE SPEED ADJUSTMENT ............... F4-24 EXHAUST SYSTEM ........... F4-29 PCM INSPECTION ..............F4-3 THROTTLE POSITIONER (T/P) ADJUSTMENT .................................................................................... MANUAL TO............................................F4-6 VACUUM HOSE ROUTING DIAGRAM .. F4-25 EXHAUST SYSTEM REMOVAL/INSTALLATION ......................F4-11/13 NONRETURN VALVE INSPECTION ......F4-16 FUEL PUMP RELAY INSPECTION .......................................F4-2 IDLE MIXTURE ADJUSTMENT ........F4-17 CARBURETOR DISASSEMBLY/ASSEMBLY ......F4-10 BEFORE REPAIR PROCEDURE...................................... F4-27 CONTROL SYSTEM ..............BACK..........................................F4-15 FUEL LINE FLOW AMOUNT INSPECTION .F4-17 CARBURETOR REMOVAL/INSTALLATION .......................................F4-14 FUEL GAUGE SENDER UNIT INSPECTION ...........................F4-8 ACCELERATOR PEDAL REMOVAL/INSTALLATION .................... F4-33 SYMPTOM TROUBLESHOOTING .... F4-29 PTC HEATER RELAY INSPECTION .....F4-9 ACCELERATOR CABLE INSPECTION/ADJUSTMENT ...............................F4-6 INTAKE-AIR SYSTEM REMOVAL/INSTALLATION .............................................................MAIN..................F4-16 DASHPOT (D/P) INSPECTION ........ F4-27 PCV VALVE INSPECTION .......................................... F4-25 EXHAUST SYSTEM INSPECTION ..................................F4-8 VACUUM CONTROL DIAPHRAGM INSPECTION ...................................................................................INDEX RANG. F4-32 QUICK DIAGNOSTIC CHART ........................................... F4-28 COMPONENT LOCATION ................TO........ F4-24 SLOW FUEL CUT SOLENOID VALVE INSPECTION .......F4-2 IGNITION TIMING ADJUSTMENT ............................................ F4-27 CLOSED THROTTLE POSITION (CTP) SWITCH ADJUSTMENT ..... F4-34/47 CONTINUED F4-1 .............................................................................................................................................................F4-13 FUEL PUMP UNIT REMOVAL/INSTALLATION.........................................................REPAIR MANUAL PAGES..........F4-16/17 SERVO DIAPHRAGM REMOVAL/INSTALLATION ............................. F4-32 FOREWORD ............ FROM..............F4-2/3 DASHPOT (D/P) ADJUSTMENT .......................... F4-26/27 WATER THERMO VALVE REMOVAL/INSTALLATION .....F4-10 AFTER REPAIR PROCEDURE . F4-26 ROLLOVER VALVE INSPECTION .................................... F4-9 FUEL SYSTEM ............................... F4-30 THROTTLE POSITIONER T/P) SOLENOID VALVE INSPECTION ..... F4-24 PTC HEATER INSPECTION ..................................................................... F4-26 CHECK VALVE (TWO-WAY) INSPECTION ..........................................................1 PURGE CONTROL VALVE INSPECTION ...............................................................F4-8 IDLE COMPENSATOR INSPECTION ......................... F4-26 N0....................F4-3/4 A/C IDLE-UP ADJUSTMENT .................................................... F4-26 CHARCOAL CANISTER INSPECTION ..................................F4-13 FUEL PUMP UNIT DISASSEMBLY/ASSEMBLY ........................F4-2 ENGINE TUNE-UP PREPARATION ...............................................................F4-8 AIR THERMO VALVE INSPECTION ...... F4-30 WATER THERMOSWITCH (INTAKE MANIFOLD SIDE) INSPECTION .....................................F4-10 FUEL TANK REMOVAL/INSTALLATION ...................................................................................................INDEX FUEL AND EMISSION CONTROL SYSTEMS (F2 CARB) ENGINE TUNE-UP ....DRFT........ F4-26 WATER THERMO VALVE INSPECTION ............................................................................................... F4-30/31 WATER THERMOSWITCH REMOVAL/INSTALLATION ..................................................... F4-26 AIR VENT SOLENOID INSPECTION ...........................................F4-14 FUEL PUMP INSPECTION ..........F4-13/14 FUEL GAUGE SENDER UNIT REMOVAL/INSTALLATION ........... F4-32 TROUBLESHOOTING ITEM TABLE ........F4-4/5 INTAKE-AIR SYSTEM ............................... F4-21/24 HIGH-ALTITUDE COMPENSATOR INSPECTION ....................................................................... F4-31 TROUBLESHOOTING ................................................ MODEL .........................2 PURGE CONTROL VALVE INSPECTION ..........F4-7 AIR CLEANER ELEMENT INSPECTION ................................................................. F4-26 N0.............

6.CHAPTER. etc. leaks in hoses. Connect a tacho dwell tacho tester to the engine. (GULF) Reconnect the proper vacuum hose to the port.000 rpm in neutral.BACK. Verify that the idle speed is within the specification. Perform the "ENGINE TUNE-UP PREPARATION. Verify that CO concentration in exhaust gas at the tail pipe during idling is as specified in the table below.5) 5. 3.INDEX RANG. FROM. CO concentration (%) 2.0 (2. 3. Make sure all accessories are OFF. If not within the specification.0 ) 2.5 ±0. IDLE MIXTURE ADJUSTMENT 1. If not within the specification.0—2. Disconnect the vacuum hose for vacuum spark advance between the distributor and the carburetor at the distributor side and plug it. Check the condition of the engine (plugs. Remove the blind cap. IGNITION TIMING ADJUSTMENT 1. 2.0—3. Remove the spring pin. MANUAL TO. adjust the CO concentration by turning the MAS (mixture adjust screw). IDLE SPEED ADJUSTMENT 1. 2. adjust the idle speed by turning the TAS (throttle adjust screw) CONTINUED F4-2 ." 3. MODEL . For GULF General 4.REPAIR MANUAL PAGES. Attach an exhaust gas analyzer and measure the CO concentration. 3. 4. Perform the "ENGINE TUNE-UP PREPARATION" and "IDLE SPEED ADJUSTMENT. While checking the ignition timing by using a timing light.TO. 4. Specification BTDC: 5°—7°(6°±1°) 2.500—3. Perform the "ENGINE TUNE-UP PREPARATION.5 (2.INDEX ENGINE TUNE-UP ENGINE TUNE-UP ENGINE TUNE-UP PREPARATION 1.) 2.DRFT. Warm up the engine and run it for three minutes at 2. adjust the crankshaft pulley alignment mark position (yellow paint) by turning the distributor as specified.

900—2. Tightening torque 9. then tap in the spring pin as shown. If not as specified. Connect the intake manifold vacuum directly to the servo diaphragm.BACK. Specification 1. FROM.REPAIR MANUAL PAGES. Race the engine and again verify that the engine speed returns smoothly to idle speed.lbf} 7. adjust the idle speed by turning the TAS (throttle adjust screw). 4.050—1.100 (2.8—17.cm.CHAPTER. If not. Note GULF only • Run the engine at idle for 3—5 seconds.INDEX ENGINE TUNE-UP DASHPOT (D/P) ADJUSTMENT 1. 3. 4. tighten the locknut. 7." 2. Disconnect the vacuum hose from the servo diaphragm.250 (1.TO. • Run the engine at idle for 3—5 seconds. Increase the engine speed to 2. 87—156 in. Specification 1.m {100—180 kgf. 8. and verify that the engine speed is as specified. Perform the "ENGINE TUNE-UP PREPARATION" and "IDLE SPEED ADJUSTMENT" 2. Pull the throttle lever until the rod and arm of the dashpot separate. Disconnect the vacuum hose for vacuum spark advance between the distributor and the carburetor at the distributor side and plug it. then fit a blind cap to the MAS (mixture adjust screw) of the vehicles for the following markets. DASHPOT (D/P) INSPECTION) THROTTLE POSITIONER (T/P) ADJUSTMENT GULF only 1.DRFT. If not within the specification. 8. then verify that the engine speed is as specified when the arm contacts the rod. repeat the above procedure to adjust the idle speed or D/P inspect (Refer to FUEL SYSTEM.500 rpm. 6. MANUAL TO. Perform the "ENGINE TUNE-UP PREPARATION" and "IDLE SPEED ADJUSTMENT.150 ± 100) rpm CONTINUED F4-3 .INDEX RANG. Reconfirm that the engine speed is within the specification. Slowly return the throttle lever from the position above.6 N. 3.000 ± 100) rpm 5. loosen the dashpot locknut and turn the dashpot body to adjust. MODEL . After adjustment.

Connect the intake manifold vacuum directly to port A. 7. If the servo diaphragm does not operate. 12. and verify that the engine speed is as specified. 8.400—1. A/C IDLE-UP ADJUSTMENT GULF only with. Reconnect the proper vacuum hose to port B.600 (1.TO. Reconnect the proper vacuum hose to port A. Perform the "ENGINE TUNE-UP PREPARATION" and "IDLE SPEED ADJUSTMENT. Except GULF. 5." 2.INDEX RANG. CONTINUED F4-4 ." 2. adjust the engine speed by the adjust screw. 3. If not within the specification. adjust the engine speed by the adjust locknut on the dual servo diaphragm head. Verify that the servo diaphragm operates when the engine speed is raced at 2. and verify that the engine speed is as spec tied.050—1.BACK. 6. Connect the intake manifold vacuum directly to port B. MODEL . If the solenoid valve is okay. If the servo diaphragm does not operate. If the solenoid valve is okay. Verify that the servo diaphragm operates when the A/C is operated. and verify that the engine speed is as specified. After adjusting the engine speed reconnect the vacuum hose to the proper port.150 ±100) rpm 9. replace the dual servo diaphragm. 3.250 (1. 8. A/C 1. After adjusting the engine speed. 7. Specification 1. Connect the intake manifold vacuum directly to the servo diaphragm. Specification 1. 6. FROM. Perform the "ENGINE TUNE-UP PREPARATION" and "IDLE SPEED ADJUSTMENT. reconnect the vacuum hose to the proper port. MANUAL TO. replace the servo diaphragm. with A/C 1. If not within the specification.500 ± 100) rpm 4. inspect the A/C idle-up solenoid valve or T/P solenoid valve. Disconnect the vacuum hose from port B. adjust the engine speed by the adjust screw.REPAIR MANUAL PAGES. 11. If not within the specification.CHAPTER. inspect the T/P solenoid valve.000 rpm or more. 13.DRFT. Disconnect the vacuum hose from the servo diaphragm. Disconnect the vacuum hose for vacuum spark advance between the distributor and the carburetor at the distributor side and plug it. Disconnect the vacuum hose from port A. 10.INDEX ENGINE TUNE-UP 5.

5. 6. CONTINUED F4-5 . inspect the A/C idle-up solenoid valve. Reconnect the proper vacuum hose to port.500 ± 100) rpm 4. Verify that the servo diaphragm operates when the A/C is operated.600 (1. FROM.400—1. If the servo diaphragm does not operate. MODEL . MANUAL TO.INDEX RANG. replace the servo diaphragm.REPAIR MANUAL PAGES. 8.BACK.TO. After adjusting the engine speed reconnect the vacuum hose to the proper port.DRFT.INDEX ENGINE TUNE-UP Specification 1. adjust the engine speed by adjust screw.CHAPTER. If not within the specification. 7. If the solenoid valve is okay.

INDEX INTAKE-AIR SYSTEM INTAKE-AIR SYSTEM VACUUM HOSE ROUTING DIAGRAM 1 2 3 4 5 6 7 8 9 10 11 Air cleaner Carburetor Vacuum control diaphragm Idle compensator Air thermos sensor FICB solenoid valve High-altitude compensator FICB diaphragm Charcoal canister No. MANUAL TO.DRFT.REPAIR MANUAL PAGES.1 purge control valve Water thermo valve 12 Distributor 13 14 15 16 17 18 19 20 21 22 T/P solenoid valve Servo diaphragm A/C idle-up solenoid valve Dual servo diaphragm To intake manifold Fuel main line (to fuel tank) Fuel return line (to fuel tank) To charcoal canister or ventilation To carburetor To check valve (two-way) CONTINUED F4-6 .INDEX RANG. FROM. MODEL .CHAPTER.BACK.TO.

It can easily ignite. WATER THERMO VALVE REMOVAL/INSTALLATION Servo diaphragm 10 11 12 CONTINUED F4-7 .DRFT.BACK. Remove in the order indicated in the table. Drain the engine coolant from the radiator.CHAPTER. 4. Always keep sparks and flames away from fuel. air thermo sensor) Air cleaner element Carburetor Fuel hose Accelerator cable PTC heater gasket PTC heater 8 9 Intake manifold Water thermoswitch ☞ CONTROL SYSTEM. (Refer to Section E. always complete the "Fuel Line Safety Procedures". they can badly bum. FROM. Turn off the engine and wait until they are cool before removing the intake-air system. (Refer to FUEL SYSTEM. shutter valve. 1 2 3 4 5 6 7 Air cleaner (in idle compensator.INDEX INTAKE-AIR SYSTEM INTAKE . WATER THERMOSWITCH REMOVAL/INSTALLATION Intake manifold gasket Water thermo valve ☞ FUEL SYSTEM. Disconnect the negative battery cable. vacuum control diaphragm.INDEX RANG. Install in the reverse order of removal. • Fuel line spills and leakage are dangerous. MANUAL TO. 2.) 1. Fuel can also irritate skin and eyes. MODEL . • Fuel vapor is hazardous.) 3. Fuel can ignite and cause serious injuries or death and damage. BEFORE REPAIR PROCEDURE.REPAIR MANUAL PAGES.AIR SYSTEM REMOVAL/INSTALLATION Warning • When the engine and intake-air system are hot. To prevent this.TO. causing serious injury and damage.

8 °F} AIR THERMO VALVE INSPECTION Note Perform the following test only when directed. Disconnect the vacuum hose from the vacuum control diaphragm. replace the idle compensator.INDEX INTAKE-AIR SYSTEM AIR CLEANER ELEMENT INSPECTION • Visually check the air cleaner element for excessive dirt.REPAIR MANUAL PAGES. Apply more than 24 KPa {180 mmHg. replace the idle compensator as an assembly. 2. damage or oil.CHAPTER. replace the air thermo valve. Confirm that the valve is in the closed position when the bimetal temperature is lower than the specified temperature. When the bimetal temperature is more than approx. 2. 4. Warm up (above 30 °C {86 °F}) the engine and verify that vacuum is not felt. If excessive air leakage is found.8 °F}. suck air from the tube A. Connect a vacuum pump to the vacuum control diaphragm. VACUUM CONTROL DIAPHRAGM INSPECTION 1. Replace the vacuum control diaphragm if not as specified. • 1. confirm that the valve is in the open position.DRFT.TO.087 inHg} vacuum and verify that the shutter valve is opened to the hot position.4—159. 7. IDLE COMPENSATOR INSPECTION 1. 3. FROM. 2. Verify that vacuum is felt at the vacuum hose when the engine is cold (below 30 °C {86 °F}) and idling. 3. replace if necessary. CONTINUED F4-8 . 3. 4.BACK. Opening temperature 63—71 °C {145. MODEL . If the valve is not open. Disconnect the vacuum hose from the vacuum control diaphragm.INDEX RANG. MANUAL TO. If vacuum condition is not as specified in Steps 2 and 3. To check. 71 °C {159.

INDEX RANG. 2. Measure the free play of the accelerator cable.CHAPTER. If not as specified. adjust by turning locknut A. Free play 1—3 mm {0.BACK.REPAIR MANUAL PAGES. 2. MODEL . Verify that the throttle valve is entirely closed. FROM. Install in the reverse order of removal. MANUAL TO.04—0.TO. CONTINUED F4-9 .DRFT.11 in} 3. 1 2 Accelerator cable ☞ ACCELERATOR CABLE INSPECTION/ADJUSTMENT Accelerator pedal ACCELERATOR CABLE INSPECTION/ADJUSTMENT 1. Remove in the order indicated in the table.INDEX INTAKE-AIR SYSTEM ACCELERATOR PEDAL REMOVAL/INSTALLATION 1.

3. Remove the fuel-filler cap and release the pressure in the fuel tank. 5. fit the hose onto the pipe over 25 mm {0. When the pipe has a stopper. 6. When installing the fuel hose. avoiding the original clamp position.BACK. Turn off the ignition switch. crank the engine several times. FROM. MANUAL TO. causing serious injury and damage. Fuel can also irritate skin and eyes. CONTINUED F4-10 . Fuel can ignite and cause serious injuries or death and damage. It can easily ignite. Reconnect the fuel pump relay connector.DRFT.REPAIR MANUAL PAGES. always complete the following "Fuel Line Safety Procedures". After the engine stalls. fit the hose until it contacts the stopper. To prevent this.INDEX FUEL SYSTEM FUEL SYSTEM BEFORE REPAIR PROCEDURE Warning • Fuel vapor is hazardous. Fuel Hose Installation 1. 2. 2. MODEL . AFTER REPAIR PROCEDURE Warning • Fuel line spills and leakage are dangerous. and hose clamps. Start the engine. Fuel can ignite and cause serious injuries or death and damage. Install a hose clamp over the fuel hose within the clamp installation range as shown.INDEX RANG. 3. Always keep sparks and flames away from fuel.CHAPTER. • Fuel line spills and leakage are dangerous. Replace damaged or deformed fuel hoses. Disconnect the fuel pump relay connector located under the passenger's side front side trim.98 in}. 4. observe "Fuel Hose Installation" and described below. fuel pipes.TO. When installing the fuel hose onto the fuel pipe. Fuel Line Safety Procedures Note Fuel in the fuel system is under high • pressure also when the engine is not running. 1.

BEFORE REPAIR PROCEDURE.INDEX FUEL SYSTEM RANG. Level the vehicle. • Fuel line spills and leakage are dangerous. 1. Complete the "AFTER REPAIR PROCEDURE".INDEX FUEL TANK REMOVAL/INSTALLATION Warning • Repairing a fuel tank that has not been properly steam cleaned can be dangerous. 7.BACK. Remove in the order indicated in the table. MODEL . do not damage the sealing surface of the fuel pump unit when removing or installing. Install in the reverse order of removal.REPAIR MANUAL PAGES. Complete the "BEFORE REPAIR PROCEDURE". Explosion or fire may cause death or serious injury.DRFT. To prevent this.CHAPTER. 3. 4. (Refer to FUEL SYSTEM.TO. Always properly steam clean a fuel tank before repairing it. AFTER REPAIR PROCEDURE. 6. 2. (Refer to FUEL SYSTEM.) Disconnect the negative battery cable. FROM. Fuel can ignite and cause serious injuries or death and damage. Fuel can also irritate skin and eyes. Drain the fuel from the drain plug.) DOUBLE CAB CONTINUED F4-11 . 5. MANUAL TO.

DRFT.Installation Note 7 8 9 Rollover valve Fuel pump unit Fuel-filler pipe 10 Dust cover 11 Fuel inlet pipe 12 Non return valve Evaporative gas check valve (two-way) 13 ☞ Installation Note CONTINUED F4-12 . FROM.TO.INDEX RANG.BACK.REPAIR MANUAL PAGES. MANUAL TO.INDEX FUEL SYSTEM REGULAR CAB 1 2 3 4 5 6 Joint hose ☞ Installation Note Breather hose w Installation Note Under guard Fuel hose Fuel tank Evaporative hose . MODEL .CHAPTER.

Disassemble in the order indicated in the table.98 in} RANG. FUEL TANK REMOVAL/INSTALLATION. do not damage the sealing surface of the fuel pump unit when removing or installing.5 in} 3. Fuel can also irritate skin and eyes.BACK. Joint Hose Installation Note Fit the joint hose onto the respective fittings • within the specification.DRFT. and install clamps as shown. FROM.) FUEL PUMP UNIT DISASSEMBLY/ASSEMBLY Warning • Fuel line spills and leakage are dangerous. Evaporative Hose Installation Note Fit each hose onto the respective fittings within • the specification. Length Breather hose: 25—30 mm {0.99—1. F4-13 CONTINUED . Length Joint hose: 35—40 mm {1. FUEL PUMP UNIT REMOVAUINSTALLATION 1. Remove the fuel pump unit.5 mm {0. FUEL TANK REMOVAL/INSTALLATION.REPAIR MANUAL PAGES.18 in} NONRETURN VALVE INSPECTION 1. Assemble in the reverse order of disassembly. Install the fuel pump unit.) 2.CHAPTER. and install clamp as shown. (Refer to FUEL SYSTEM.06 in} when the nonreturn valve is returned to the closed position. Verify that the nonreturn valve opening angle is 50—56° when pushed out from the fuel inlet pipe side. Remove the nonreturn valve with the fuel inlet pipe. and install clamps as shown.INDEX FUEL SYSTEM Evaporative Gas Check Valve (Two-way) Installation Note Install the arrow mark of the evaporative gas • check valve (two-way) facing the charcoal canister. MODEL . MANUAL TO. 2. If not as specified. (Refer to FUEL SYSTEM.INDEX Breather Hose Installation Note Fit each hose onto the respective fittings within • the specification. replace the nonreturn valve. Length Evaporative hose: 25 mm {0. and the clearance between the nonreturn valve and the fuel inlet pipe end is within 1. 2. Fuel can ignite and cause serious injuries or death and damage.4—1.TO. To prevent this. 1.

Do not apply excessive side force when pushing the fuel hose onto the fuel pump nipple. pull the pump down so that it is tight against the bracket. FUEL TANK REMOVAL/INSTALLATION. Inspect for continuity between fuel pump unit connector terminals C and D. 3. Remove the fuel tank.) FUEL PUMP INSPECTION Continuity Inspection Note Perform the following test only when • directed.) 2.) FUEL GAUGE SENDER UNIT INSPECTION (Refer to Section T. FUEL TANK REMOVAL/INSTALLATION.TO. BEFORE REPAIR PROCEDURE. FUEL GAUGE SENDER UNIT INSPECTION. MANUAL TO. 1.CHAPTER. FROM. (Refer to FUEL SYSTEM. 2.REPAIR MANUAL PAGES. REGULAR CAB FUEL GAUGE SENDER UNIT REMOVAL/INSTALLATION (Refer to FUEL SYSTEM. (Refer to FUEL SYSTEM. MODEL .DRFT. Fuel Hose Assembly Note 1. Disconnect the negative battery cable.) 4.INDEX Fuel Pump Assembly Note After installing the fuel pump body to the • bracket. 1 2 3 4 5 6 7 Fuel pump unit connector Rubber mount Fuel filter (low-pressure) Clamp Fuel hose ☞ Assembly Note Fuel pump body ☞ Assembly Note Fuel gauge sender unit F4-14 CONTINUED . Complete the "BEFORE REPAIR PROCEDURE". WARNING AND INDICATOR SYSTEM.BACK.INDEX FUEL SYSTEM DOUBLE CAB RANG. Install the clamps as shown.

Complete the "BEFORE REPAIR PROCEDURE". and verify that fuel pressure is as specified. Complete the "AFTER REPAIR PROCEDURE".CHAPTER. Repair or replace faulty areas. (Refer to FUEL SYSTEM.) 2. 2.INDEX FUEL SYSTEM RANG. 4.REPAIR MANUAL PAGES. If there is no continuity. AFTER REPAIR PROCEDURE. Connect the C and D terminals of the fuel pump relay with a jumper wire. 1. FUEL PUMP RELAY INSPECTION. 5.25 kgf/cm . Disconnect the main fuel hose (A). If the harnesses are okay.20—0. Turn the ignition switch ON. HARNESS SIDE CONNECTOR (VIEW FROM TERMINAL SIDE) Short circuit Fuel pump relay connector terminal C and • fuel pump unit connector terminal D through common connector to GND 6. CONTINUED F4-15 . 3. perform the fuel pump inspection.) 8.) 7. Connect the negative battery cable.) FUEL LINE PRESSURE INSPECTION Note • Perform the following test only when directed. 6.TO. BEFORE REPAIR PROCEDURE.) 2. If not as specified. Install the fuel tank. 3. MODEL . (Refer to FUEL SYSTEM. 9. replace the fuel pump body. 1. inspect the fuel pump relay.BACK. Reconnect the negative battery cable. Complete the "BEFORE REPAIR PROCEDURE". Specification 2 20—25kPa {0. Disconnect the main fuel hose (A). If there is continuity in the fuel pump but the fuel pump does not operate. Connect the C and D terminals of the fuel pump relay with a jumper wire. FUEL TANK REMOVAL/INSTALLATION. Open circuit • GND circuit (fuel pump unit connector terminal C and body GND) • Power circuit (fuel pump relay connector terminal C and fuel pump unit connector terminal D through common connector) HARNESS SIDE CONNECTOR (VIEW FROM TERMINAL SIDE) 5. MANUAL TO. (Refer to FUEL PUMP INSPECTION. and insert the end into a measuring beaker. (Refer to FUEL SYSTEM. (Refer to FUEL SYSTEM. and connect a fuel pressure gauge to it.6 psi} 7. (Refer to FUEL SYSTEM. FROM. Disconnect the negative battery cable. inspect as follows and repair or replace as necessary. BEFORE REPAIR PROCEDURE.INDEX 4. Disconnect the negative battery cable.8—3.) FUEL LINE FLOW AMOUNT INSPECTION Note • Perform the following test only when directed.DRFT.

5. Start the engine. perform the fuel pump inspection. Remove the fuel pump relay. Verify that clicking sound is heard or vibration is felt from the fuel pump relay white cranking the engine.150 cc {70. MANUAL TO. D and ignition switch IG1) GND circuit (fuel pump relay connector terminal B and PCM terminal H) DASHPOT (D/P) INSPECTION 1. 3.2 cu in} min. Off-Vehicle Inspection 1. 2. D • and ignition switch IG1 to GND. Open the throttle valve fully then push the dash pot rod with a finger and make sure the rod goes into the dash pot slowly. Inspect for continuity between the fuel pump relay terminals by using an ohmmeter. MODEL . 4. Turn the ignition switch on.INDEX RANG. 5. Stop the engine.000 rpm. If not as specified. FROM. 2. Warm up the engine to normal operation temperature.BACK. but do not touch the accelerator pedal. Plug the hoses of the idle compensator.000—4.REPAIR MANUAL PAGES. CONTINUED F4-16 . 2. Verify that the engine speed is 3. Crank the engine while touching the fuel pump relay by hand. Drive the fuel pump for a minute and verify that the fuel flow amount is within the specification. Short circuit Fuel pump relay connector terminal A. 1. then release the choke valve after releasing the throttle valve.DRFT. turn the adjust screw to adjust.) FAST IDLE SPEED ADJUSTMENT 1. 6. 6. 7.INDEX FUEL SYSTEM 5. inspect the harness for the following. If the engine speed is not as specified. Connect the negative battery cable. Remove the front left side trim. Release the finger and make sure the rod comes out quickly. push the choke fully closed. (Refer to FUEL PUMP INSPECTION. If there is no clicking sound or vibration. If the harnesses are okay.TO. Open circuit • • Power circuit (fuel pump relay connector terminal A. While holding the throttle valve slightly open. 3. FUEL PUMP RELAY INSPECTION On-Vehicle Inspection Note • Perform the following test only when directed. Specification More than 1.CHAPTER. 4. 2. perform the following off-vehicle inspection.

INDEX Tightening torque 9. 5.m {100—250 kgf. 87—216 in. Tightening torque 19—25N.6 kgf. MODEL .lbf} 6. SERVO DIAPHRAGM REMOVAL/INSTALLATION 1.8—24 N. 4.m {1. Install the servo diaphragm onto the bracket. If not as specified. 2. Tighten the installation nut to the specification. then hand-tighten the installation nut.DRFT. 3. 14—18ft.m. FROM.REPAIR MANUAL PAGES.cm-cm.BACK.lbf} CARBURETOR REMOVAL/INSTALLATION (Refer to INTAKE-AIR SYSTEM INTAKE-AIR SYSTEM REMOVAL/INSTALLATION. Install the servo diaphragm bracket to the intake manifold. Separate the servo diaphragm from the bracket. MANUAL TO. Loosen the servo diaphragm installation nut.) 3.9—2.CHAPTER.INDEX FUEL SYSTEM RANG.TO. Remove the servo diaphragm and the servo diaphragm bracket from the intake manifold. replace the fuel pump relay. CONTINUED F4-17 .

gaskets. CONTINUED F4-18 . MODEL . (Refer to Carburetor After Assembly Note.INDEX RANG.BACK.TO.DRFT.CHAPTER. Disassemble in the order indicated in the table. If not.INDEX FUEL SYSTEM CARBURETOR DISASSEMBLY/ASSEMBLY 1. and washers when assembling the carburetor. 2. it will possibly cause a malfunction. FROM.REPAIR MANUAL PAGES.) • Caution Replace the O-rings. Assemble in the reverse order of disassembly. MANUAL TO.

BACK. high-altitude models) 4 5 Air vent solenoid valve lead (separate from the connector) Disconnect choke rod 10 Slow fuel cut solenoid valve 11 Accelerator pump outlet check ball and spring 12 Accelerator pump inlet check ball 13 Primary slow jet 14 Secondary slow jet 15 Primary main jet 16 Secondary main jet 17 Primary venturi and nozzle 18 Secondary venturi and nozzle 19 Primary main air bleed 20 Secondary main air bleed 21 Main body 22 Vacuum diaphragm 23 Throttle body 24 Mixture adjust screw 25 Bimetal 26 Choke breaker diaphragm 27 Power jet 7 6 Air horn and automatic choke assembly (separate from main body) Air vent solenoid valve. and gasket. 2.INDEX RANG.CHAPTER. spring. Disassemble in the order indicated in the table. spring.TO. and lever Connect spring CONTINUED F4-19 .DRFT. FROM. Disassemble in the order indicated in the table.REPAIR MANUAL PAGES. MANUAL TO. 1 2 Float and pin Needle valve assembly 1 2 3 Vacuum hose Accelerator pump connecting rod. 2. MODEL .D. Air Horn and Automatic Choke Disassembly/Assembly 1.INDEX FUEL SYSTEM 1 2 3 4 5 6 7 8 9 Accelerator pump connecting rod Connect spring Air vent solenoid valve Choke rod Air horn Float Needle valve assembly Accelerator pump plunger Closed throttle position (CTP) switch (GENERAL (LH.). Assemble in the reverse order of disassembly. Assemble in the reverse order of disassembly. if necessary Needle Valve and Float Disassembly/Assembly 1.

REPAIR MANUAL PAGES.DRFT. be sure to adjust it. 2. and gasket.1) 14 Coasting richer jet 8 9 Disconnect vacuum diaphragm connecting rod Throttle body (separate from main body) Main Body Disassembly/Assembly Caution • After installing the idle switch.1) Primary main jet Primary slow air bleed (No.BACK. 2. Disassemble in the order indicated in the table. FROM.INDEX RANG. Disassemble in the order indicated in the table. spring.2) 12 Secondary slow air bleed (No.2) 13 Coasting richer air bleed (No. Assemble in the reverse order of disassembly.2) 3 CTP switch and spring Slow fuel cut solenoid valve. 10 Vacuum diaphragm assembly and gasket CONTINUED F4-20 . 1 2 1 2 3 4 5 6 7 8 9 Secondary slow jet Secondary slow air bleed (No. MODEL .INDEX FUEL SYSTEM Air Bleeds and Jets Disassembly/Assembly 1. 1.CHAPTER. Assemble in the reverse order of disassembly. 10 Power jet Accelerator pump plunger assembly and spring Retaining clip Strainer and accelerator pump inlet check ball Check valve plug Accelerator pump outlet check ball and spring • Caution Note the size of all jets and air bleeds so that they will be reassembled in the correct position 4 5 6 7 Note • One bolt is inside the throttle body 11 Coasting richer air bleed (No. MANUAL TO. needle valve.TO.1) Secondary main air bleed Secondary main jet Primary main air bleed Slow jet and plug Primary slow air bleed (No.

arms. CONTINUED F4-21 . (3) After the idle adjustment is completed. CARBURETOR INSPECTION/ADJUSTMENT Body.INDEX FUEL SYSTEM RANG. and wear on the contact surface of the throttle valve shaft. If necessary. 4. Valve. 2. Check for deformity.REPAIR MANUAL PAGES. replace it.DRFT. Check for cracks on the air horn. distortion on the installing surface attached to the main body. and wear on the levers. 2.INDEX 11 Diaphragm cover screws and cover 12 Spring and diaphragm 13 Accelerator cable hanger Throttle Body Disassembly/Assembly Caution • Do not remove the throttle valve and shaft. or deform the port of the jets and become the cause of malfunctions. Check the taper part of the MAS. (5) After the idle adjustment has been completed. crack. If necessary. press in the spring pin. the Venturis. 1. If necessary. replace it. solenoid valves. Carburetor After Assembly Note • Install the carburetor in the reverse order of removal. bends. (1) Start the engine and check for leaks. and wear. note the following. replace it. Caution • Do not use a piece of wire to clean the jets. If necessary. Check for clogging in jets and air bleeds. replace it. 3. FROM. After installation. replace it.TO.BACK. (1) When removing the mixture adjust screw. Jet 1. The wire may scratch. and wear on the contact surface of the choke valve shaft. Assemble in the reverse order of disassembly. tap out the spring pin as shown in the figure. If necessary. Check the rubber part of the accelerator pump for cracks and damage. 5. (2) Make the idle adjustment. check the fast idle speed as follows. and needle valve (float) for cracks and dents. 6. and connecting rods. MANUAL TO.CHAPTER. MODEL . or the choke valve and shaft. clean with clean gasoline or kerosene and dry with compressed air. If necessary. Disassemble in the following order. Check for cracks and distortion on the throttle body. (4) Adjust the CTP switch.

CONTINUED F4-22 .CHAPTER. 2. and check the clearance R. 15. Use a vacuum pump to apply approximately 53 kPa {400 mmHg. adjust by bending the choke lever D. replace the diaphragm.22 mm {0.TO.732—1.068—0. MANUAL TO.BACK. If not as specified.DRFT. If the rod returns to the original position.INDEX FUEL SYSTEM Diaphragms 1. Push the choke valve lightly to close it. 3.772 in} 4. FROM.72—2. Float Level Adjusting 1.087 In} 3. bend the float seat lip A until the proper clearance is obtained. Measure the clearance L between the bottom of the float and air horn. If the clearance is not as specified. Measure the clearance H between the float and air horn.315—0.354 in} 2. If not as specified. Clearance L 44—45 mm {1. Clearance H 8—9 mm {0. bend the float stopper B until the proper clearance is obtained. MODEL . 2.7 inHg} vacuum to the choke diaphragm.REPAIR MANUAL PAGES. Clearance R 1. Choke Valve 1. 3. Verify that the rod does not return when the port is plugged. Push the rod fully and plug the port by hand.INDEX RANG.

bend tab B to adjust.70 mm {0. Measure the choke valve clearance R.) Clearance G 0. Clearance R 0.INDEX FUEL SYSTEM Fast-idle cam 1. 3. MODEL . Open the primary throttle valve fully. The secondary throttle valve should start to open when the primary throttle valve opens 48 ° —52 ° and should be completely open at the same time the primary throttle valve is fully open. 2. Secondary throttle valve 1.64—0. adjust the choke valve clearance R by bending the starting arm B.024—0.025—0. 4.146 in} 3. Unloader system 1. Set the fast-idle cam to the second highest position. 2. adjust by bending tab A.DRFT. If the clearance is not as specified. If the clearance is not as specified. MANUAL TO.CHAPTER. If necessary. Clearance R 2.INDEX RANG. Adjust the throttle valve clearance G by turning the adjust screw. If large adjustments are required.60—1.033 in} 3.REPAIR MANUAL PAGES. 2. the choke rod should be bent.047 in} 5. (The clearance becomes larger as the screw is turned clockwise.BACK.20 mm {0.84 mm {0. Set the fast idle cam at the second highest position. FROM. Check the choke valve clearance R. Check the clearance between the primary throttle valve and the throttle bore when the secondary throttle valve starts to open.TO. CONTINUED F4-23 .82—3.111—0.

Run the engine at idle speed.325 in} HIGH-ALTITUDE COMPENSATOR INSPECTION 1.INDEX FUEL SYSTEM Clearance R 7.DRFT. Disconnect the carburetor connector and verify that the engine stops. SLOW FUEL CUT SOLENOID VALVE INSPECTION Operation Inspection Note • Perform the following test only when directed.REPAIR MANUAL PAGES. Connect an ohmmeter between the connector and the intake manifold. Disconnect each air hose from the carburetor. 3.640 ft } (Low altitude): Air does not pass. MODEL . replace the slow fuel cut solenoid valve. 500m {1. If the engine does not stop. If not as specified. PTC HEATER INSPECTION 1. Disconnect the PTC heater connector. 2.INDEX RANG. MANUAL TO. replace the high-altitude compensator. 2.TO.25 mm {0. Check the high-altitude compensator by blowing through each hose. Disconnect the carburetor connector (6-pin). 2. and verify continuity. CONTINUED F4-24 . FROM. 1.BACK. 3.640 ft} or higher (High altitude): Air passes. Less than 500 m {1.CHAPTER.289—0. 3. If it is not correct.35—8. 4. replace the PTC heater.

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

(Refer to FUEL SYSTEM.9 kPa {+22 mmHg. 3. Touch the finger onto the air vent solenoid valve. Put the threaded part in a water-filled container and slowly increase the water temperature. Blow air into port A and verify that there is airflow. 4. MANUAL TO. ROLLOVER VALVE INSPECTION 1.1 PURGE CONTROL VALVE INSPECTION 1. Remove the charcoal canister. 2. Blow into the hose and make sure air flows freely.29 inHg} to port A Airflow No Yes Yes 3.87 inHg} to port A Apply pressure over +5.BACK. Condition Apply pressure below +2. 3. Replace the charcoal canister if necessary. CONTINUED F4-26 .98 KPa {-7. 2.36 mmHg. If not as specified. If not as specified. MODEL . -4.DRFT.9 kPa {+44 mmHg. +1. +0. Hold the valve as shown. 2. 2. Remove the air cleaner. WATER THERMO VALVE INSPECTION 1. 2. Shake the charcoal canister upside down and verify that no pieces of charcoal falls from either nipple.33 inHg} or above and blow through port A again. FROM. N0.REPAIR MANUAL PAGES.INDEX EMISSION SYSTEM EMISSION SYSTEM N0.2 PURGE CONTROL VALVE INSPECTION 1. Visually check the charcoal canister for damage and leakage.7 KPa {-110 mmHg. 2. Remove the water thermo valve. CHECK VALVE (TWO-WAY) INSPECTION 1. Verify that air flows from port A. 3. CHARCOAL CANISTER INSPECTION 1. -0. Turn the ignition switch to "ON" and "OFF". Blow through port A and verify that air does not flow.7 inHg} to port A Apply pressure over -0. Disconnect vacuum hose B from the pipe. Port A-B C-D Condition Below 50°C {122°F} Above50°C {122°F} No Airflow Airflow Airflow No Airflow 3.FUEL TANK REMOVAL/INSTALLATION. Remove the rollover valve.) 2.TO. If not as specified. replace the charcoal canister. 4. replace the water thermo valve.CHAPTER. If there is a "clicking" noise. Remove the check valve (two-way). 3. Connect a vacuum pump and apply vacuum of -14. AIR VENT SOLENOID INSPECTION 1. the air vent solenoid valve is working properly. replace the check valve (twoway).INDEX RANG. Inspect airflow of the valve under the following conditions. Check the airflow of the valve under the following conditions.

5—4. Blow air into port A and verify that there is no airflow. Tightening torque 25—39 N. If not as specified.m-m. 2. 2.200 (1. replace the rollover valve. Specification Water temperature (°C {°F}) Below 67 {153} Above 67 {153} Continuity Yes No Blow from port B No 3. Turn the valve upside-down as shown. ENGINE COOLANT REPLACEMENT. and heat the water gradually.000—1. COOLING SYSTEM. Wrap sealing tape two or three times around the threaded part of the valve before installing. Increase the engine speed to more than 2. Drain the coolant into a container.lbf} PCV VALVE INSPECTION 1. 4. (Refer to Section E.REPAIR MANUAL PAGES. Warm up the engine and run it at idle. Drain the engine coolant.DRFT. Connect a dwell tacho tester to the engine. Remove the flange thermoswitch from the carburetor. (Refer to Section E. FLANGE THERMOSWITCH INSPECTION Note • Perform the following test only when directed. MODEL . If not as specified.0 kgf. Remove the water thermo valve from the intake manifold.) 2.INDEX EMISSION SYSTEM 3. 12 V Less than 1. If not as specified. replace the PCV valve. CLOSED THROTTLE POSITION (CTP) SWITCH ADJUSTMENT 1. CONTINUED F4-27 . Use a new washer and install in the reverse order of removal.000 rpm. ENGINE COOLANT.INDEX RANG. 5.5 V 4. Engine speed At idle 1. 4.BACK. Condition Blow from port A Airflow Yes 4. turn the adjust screw to adjust. WATER THERMO VALVE REMOVAL/NSTALLATION 1. Inspect the thermoswitch terminals by using an ohmmeter. MANUAL TO. 3. decelerate gradually and verify that the volt meter indicates as follows. 19—28 ft. Connect a voltmeter to the CTP switch terminal.TO.m {2. If not as specified. 5. Place the thermoswitch in water with a thermometer. ENGINE COOLANT REPLACEMENT.100 ±100) rpm Voltage Approx. 3. replace the flange thermoswitch.) 2. 3. FROM.CHAPTER. Check the airflow of the valve under the following conditions. Continuity Inspection 1. Remove the PCV valve.

BACK.INDEX RANG.CHAPTER.TO. MANUAL TO.INDEX CONTROL SYSTEM CONTROL SYSTEM COMPONENT LOCATION 1 2 3 Ignition coil Water thermoswitch PCM 4 5 6 T/P solenoid valve (GULF only) PTC heater relay Fuel pump relay CONTINUED F4-28 . FROM. MODEL .DRFT.REPAIR MANUAL PAGES.

INDEX CONTROL SYSTEM PCM REMOVAL/INSTALLATION 1. 2. Reconnect PCM connector and battery negative terminal. Remove in the order indicated in the table. Remove the front left side trim. 4. Note With the PCM connector connected. FROM.TO. and PCM to determine the cause of trouble.0 Below 1.0 Below 1.REPAIR MANUAL PAGES. Always carry out a total inspection of the input systems. 3. wiring harnesses and connectors referring to the Action column in the terminal voltage list.BACK.CHAPTER. MANUAL TO. Measure the voltage at PCM terminal using a voltmeter.0 — B+ — ON — B+ • • • • H Fuel pump control PTC heater control • • Fuel pump relay PTC heater relay • • • • • • • • • I Coolant temperature Water thermoswitch Coolant temperature • J Fuel pump control PTC heater control • • Fuel pump relay PTC heater relay • *: GULF only F4-29 CONTINUED . If any incorrect voltage is detected.0 Action • • • • • T/P solenoid valve Related wiring harnesses Related wiring harnesses FICB solenoid valve Related wiring harnesses Igniter Related wiring harnesses — Ignition SW Related wiring harnesses — Fuel pump relay PTC heater relay Related wiring Water thermoswitch Related wiring harnesses Fuel pump relay PTC heater relay Related wiring harnesses B C FICB control FICB solenoid valve D E F G Ignition — IG1 — Igniter Ignition SW ON — Ignition SW — Ignition SW OFF — ON Ignition SW OFF Below 40°C {104°F} Above 40°C {104°F} ON Ignition SW OFF Below 1. 2.0 B+ 0V B+ Below 1. 4.0 B+ Below 1. a wrong diagnosis will be made. PCM INSPECTION Caution • The PCM terminal voltages vary with change in measuring conditions and vehicle conditions. Install in the reverse order of removal.INDEX RANG. • Terminal *A Signal Throttle positioner control — Connected to T/P solenoid valve GND Test condition Below 1500 rpm Engine speed Above 1500 rpm Constant Coolant temperature Ignition SW Other Idle Below 40°C {104°F} ON Voltage (V) B+ Below 1. 3. PCM Terminal Voltage (Reference) 1.0 Approx 11V • Below 1. body ground the voltmeter negative (-) lead and measure voltage at each PCM terminal by inserting the voltmeter positive (+) lead.DRFT. Remove the PCM. Disconnect the negative battery cable. MODEL . Otherwise. inspect related systems. output systems.

500 Above 1. 1.) • GND circuit (T/P solenoid valve connector terminal B and PCM connector terminal A.INDEX RANG. MODEL . Repair or replace faulty areas. 3. (Refer to Section E. Connect the negative battery cable.) Short circuit • T/P solenoid valve connector terminal A and ignition switch IG1 through common connector to GND 5. 2. 3.INDEX CONTROL SYSTEM PTC HEATER RELAY INSPECTION 1. MANUAL TO. If as specified. 3.BACK. Measure the voltage as shown. If not as specified. ENGINE COOLANT REPLACEMENT. Drain the coolant into a container. Inspect for airflow between each port under the following condition. 7. Inspect for continuity between the PTC heater relay terminals by using an ohmmeter. Continuity Inspection 1. FROM. inspect the following: Vacuum hose improper routing. WATER THERMOSWITCH INSPECTION Note • Perform the following test only when directed. THROTTLE POSITIONER (T/P) SOLENOID VALVE INSPECTION Voltage Inspection Note • Perform the following test only when directed. If not as specified. Airflow Inspection 1. 4. 2. 3. Remove the PTC heater relay. Remove the T/P solenoid valve. Open circuit • Power circuit (T/P solenoid valve connector terminal A and ignition switch IG1 through common connector.REPAIR MANUAL PAGES.CHAPTER. 2. 6. Run the engine at idle. Remove the water thermoswitch from the under side of the intake manifold. Connect a voltmeter to terminals of the T/P solenoid valve as shown. Place the thermoswitch in water with a thermometer. COOLING SYSTEM. replace the PTC heater relay.0 8.500 Voltage (V) B+ Below 1. Inspect the thermoswitch terminals by using an ohmmeter. and heat the water gradually. 4. replace the T/P solenoid valve. Disconnect the negative battery cable. F4-30 CONTINUED . Engine speed (rpm) Below 1. kinks or leakage.DRFT.TO. perform the following airflow inspection.) 2. If output voltage is as shown in the table above but there is no airflow in the T/P solenoid valve. Install the T/P solenoid valve.

lbf} CONTINUED F4-31 . The wrap sealing tape two or three times around the threaded part of the switch before installing. MODEL .8 N. WATER THERMOSWITCH REMOVAL/INSTALLATION 1. 53—78 in.9—8. Tightening torque 5. ENGINE COOLANT.cm-cm.TO.CHAPTER.m {60—90 kgf.BACK. replace the water thermoswitch. Disconnect the negative battery cable. 5. FROM. If not as specified. Drain the engine coolant.INDEX RANG. Remove the water thermoswitch from the radiator.) 3.DRFT. 4.REPAIR MANUAL PAGES. Use a new washer and install in the reverse order of removal. MANUAL TO. (Refer to Section E.INDEX CONTROL SYSTEM Specification Water temperature (°C {°F}) Below 40 {104} Above 40 {104} Continuity Yes No 5. 2. ENGINE COOLANT REPLACEMENT.

BACK.TO.CHAPTER.INDEX

RANG.DRFT.REPAIR MANUAL PAGES. FROM. MANUAL

TO. MODEL .INDEX

TROUBLESHOOTING TROUBLESHOOTING
FOREWORD • Before proceeding with the following troubleshooting; (1) Refer to section Gl to understand the basic troubleshooting procedure. (2) Perform the diagnostic trouble code inspection. (3) If a diagnostic trouble code is displayed, proceed with inspection steps for the code. (4) When the engine can be started, perform "ENGINE TUNE-UP". TROUBLESHOOTING ITEM TABLE • Confirm trouble symptom by using the following diagnostic index, then go to appropriate troubleshooting chart.
No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 TROUBLESHOOTING ITEM Cranks normally but won't start or hard start DESCRIPTION No combustion

Cranks normally but won't start or hard start (always) Requires excessive cranking time (more than 5 seconds) Cranks normally but won't start or hard start (engine Requires excessive cranking of longer than 5 seconds for cold) more than 3 times for engine to start. Cranks normally but won't start or hard start (engine Requires excessive cranking time (more than 5 seconds) warm) Rough idle/engine stalls at idle (always) — Rough idle/engine stalls at idle (engine cold) Rough idle/engine stalls at idle (engine warm) Idling is stable when engine is warm. Idling is stable when engine is cold.

Rough idle/engine stalls at idle when A/C or P/S ON Engine runs normally at idle with no load, but stalls or vibrates (if equipped) excessively when load (A/C or P/S) is ON. Engine suddenly stalls often — High idle speed after warm-up Engine stalls at drive away Engine stalls on deceleration Hesitation Poor acceleration No power, fastest speed is low Knocking Afterburn occurs during deceleration Poor fuel economy — — — — — — — — —

CONTINUED

F4-32

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TROUBLESHOOTING
QUICK DIAGNOSTIC CHART Intake-air system Emission system O O O O O O O O O O O O O O O O O O O O O O O O O O O O O O O O O O O O O O O O O O O O O O O O O O O O O O Malfunctioning slow cut solenoid valve Malfunctioning air vent solenoid valve Control system Engine Fuel system
Carburetor

No

Item

Engine electrical system

1 2 3 4 5 6 7 8

Cranks normally but won't start or hard start Cranks normally but won't start or hard start (always) Cranks normally but won't start or hard start (engine cold) Cranks normally but won't start or hard start (engine warm) Rough idle/engine stalls at idle (always) Rough idle/engine stalls at idle (engine cold) Rough idle/engine stalls at idle (engine warm) Rough idle/engine stalls at idle when A/C or P/S ON (If equipped) Engine suddenly stalls often

O O O

O O O O O O O

O O O O O O O O

O O O O O O O O O O

O O O O O O O O O

O O O O O O O O O O O O O O O O O O

O

O O O

O O O

O O

O O O

9

O O O O O O O O O O O O

10 High idle speed after warm-up 11 Engine stalls at drive away 12 Engine stalls on deceleration 13 Hesitation 14 Poor acceleration 15 No power, fastest speed is low 16 Knocking 17 Afterburn occurs during deceleration 18 Poor fuel economy

O O O O O O

Misadjusted CO, HC concentration

Manufacturing accelerator pump

Misadjusted accelerator cable

Malfunctioning choke system

Malfunctioning water switch

Malfunctioning ignition coil

Malfunctioning spark plug

Malfunctioning fuel pump

Malfunctioning distributor

Clogged secondary main

Clogged secondary slow

Engine internal damage

Malfunctioning fuel line

Clogged primary main

Clogged primary slow

Malfunctioning starter

Malfunctioning hoses

Clogged air cleaner

Float lever

Measure compression pressure Spark inspection

Lower than specification No spark

O O O O

F4-33

CONTINUED

Battery

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SYMPTOM TROUBLESHOOTING:
Symptom 1-Cranks normally but will not start or hard start Symptom 2-Cranks normally but will not start or hard start (always) Symptom 3-Cranks normally but will not start or hard start (engine cold) Symptom 4-Cranks normally but will not start or hard start (engine warm) Symptom 5-Rough idle/engine stalls at idle (always) Symptom 6-Rough idle/engine stalls at idle (engine cold) Symptom 7-Rough idle/engine stalls at idle (engine warm) Symptom 8-Rough idle/engine stalls at idle-when a/c or p/s on (if equipped) Symptom 9-Engine suddenly stalls often Symptom 10-High idle speed after warm-up Symptom 11-Engine stalls at drive away Symptom 12-Engine stalls on deceleration Symptom 13-Hesitation Symptom 14-Poor acceleration Symptom 15-No power, fastest speed is low Symptom 16-Knocking Symptom 17-Afterburn occurs during deceleration Symptom 18-Poor fuel economy F4-34 F4-35 F4-36-37 F4-37 F4-38 F4-39 F4-39 F4-40 F4-40 F4-41 F4-41-42 F4-42 F4-42-43 F4-43-44 F4-44-45 F4-46 F4-46 F4-47

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TROUBLESHOOTING
SYMPTOM TROUBLESHOOTING
SYMPTOM 1 CRANKS NORMALLY BUT WON'T START OR HARD START 1. Air/Fuel mixture too lean Air leak • 2. Poor ignition or misfire 3. Slow fuel cut solenoid valve malfunction 4. Low engine compression Warning Following troubleshooting flowchart contains fuel system diagnosis and repair procedures. Read following warnings before performing fuel system service: • Fuel vapor is hazardous. It can easily Ignite, causing serious injury and damage. Always keep sparks and flames away from fuel. • Fuel line spills and teaks are dangerous. Fuel can ignite and cause serious Injuries or death and damage. Fuel can also irritate skin and eyes. To prevent this, always complete "BEFORE REPAIR PROCEDURE" and "AFTER REPAIR PROCEDURE" described in this manual. ☞ FUEL SYSTEM, BEFORE REPAIR PROCEDURE ☞ FUEL SYSTEM, AFTER REPAIR PROCEDURE RESULTS ACTION Yes Repair or replace appropriate parts. No 2 Disconnect high-tension lead at idle, then check engine speed. Does it decrease equally at each cylinder? Check float level. Is it okay? Yes No Yes No Go to next step. Go to next step. Refer to section G. Go to next step. If float level is high, check float and needle valve. If level is low, check for clogging between float to needle valve and to fuel pump, and between fuel pump to fuel tank. Check each jet and air bleed for clogging. Go to next step. Go to next step. Repair or replace spark plug. Go to step 8. Go to next step. Adjust ignition timing. Check both distributor and timing belt. Go to step 10. Go to next step. Repair or replace wiring harness between slow fuel cut solenoid valve and carburetor. Repair or replace slow fuel cut solenoid valve. Go to step 12. Go to next step. Check pistons and cylinders for wear, Check for the following: • Burnt valve • Worn piston, piston ring, or cylinder • Damaged cylinder gasket Check for the following: • Fuel filter (clogging) • Float room (dust) • Fuel hose (clogging) • Fuel tank (dust) Clean or replace each jet and air bleed.

POSSIBLE CAUSE

STEP INSPECTION 1 Check if there is any air leakage. Is there any?

3

4 5 6 7 8 9

Open and close throttle valve 2-3 times. Does engine start? Check each spark plug. Are they okay? Check ignition timing at idle. Is it okay? Perform ignition timing adjustment. Can timing be adjusted? Check slow fuel cut solenoid. Is it okay? Shake carburetor's connector (6-pin) with ignition switch at ON. Is a "click" sound heard? Check compression pressure. Is it okay? Add oil through plug hole. Does engine start?

Yes No Yes No Yes No Yes No Yes No Yes No

10 11

Yes No Yes No

12

Check primary main, slow system. Is it okay?

Yes

No

F4-34

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TROUBLESHOOTING
SYMPTOM 2 CRANKS NORMALLY BUT WON'T START OR HARD START (ALWAYS) 1. Air/Fuel mixture too lean • Air leak • Fuel level incorrect • Restricted primary main, slow system 2. Poor ignition or misfire 3. Slow fuel cut solenoid valve malfunction 4. Low engine compression 5. Air/Fuel mixture too rich • Float level incorrect • Loose primary main jet Warning Following troubleshooting flowchart contains fuel system diagnosis and repair procedures. Read following warnings before performing fuel system service: • Fuel vapor is hazardous. It can easily ignite, causing serious injury and damage. Always keep sparks and flames away from fuel. • Fuel line spills and leaks are dangerous. Fuel can ignite and cause serious injuries or death and damage. Fuel can also irritate skin and eyes. To prevent this, always complete "BEFORE REPAIR PROCEDURE" and "AFTER REPAIR PROCEDURE" described in this manual. " ☞ FUEL SYSTEM, BEFORE REPAIR PROCEDURE ☞ FUEL SYSTEM, AFTER REPAIR PROCEDURE INSPECTION Check if there is any air leakage. Is there any? Disconnect high-tension lead at idle, then check engine speed. Does it decrease equally at each cylinder? Check ignition timing at idle. Is it okay? Perform ignition timing adjustment. Can timing be adjusted? Check float level. Is it okay? RESULTS Yes No Yes No Yes No Yes No Yes No ACTION Repair or replace appropriate parts. Go to next step. Go to next step. Refer to Section G. Go to Step 8. Go to next step. Adjust ignition timing. Check both distributor and timing belt. Go to next step. If float level is high, check float and needle valve. If level is low, check for clogging between float to needle valve and to fuel pump, and between fuel pump to fuel tank. Check each jet and air bleed for clogging. Go to next step. Go to next step. Repair or replace spark plug. Go to Step 10. Go to next step. Repair or replace wiring harness between slow fuel cut solenoid valve and carburetor. Repair or replace slow fuel cut solenoid valve. Go to Step 12. Go to next step. Check pistons and cylinders for wear. Check for the following: • Burnt valve • Worn piston, piston ring, or cylinder • Damaged cylinder gasket Check for the following: • Fuel filter (clogging) • Float room (dust) • Fuel hose (clogging) • Fuel tank (dust) Clean or replace each jet and air bleed.

POSSIBLE CAUSE

STEP 1 2

3 4 5

6 7 8 9

Open and close throttle valve 2-3 times. Does engine start? Check each spark plug. Are they okay? Check slow fuel cut solenoid. Is it okay? Shake carburetor's connector (6-pin) with ignition switch at ON. Is a "click" sound heard? Check compression pressure. Is it okay? Add oil through plug hole. Does engine start?

Yes No Yes No Yes No Yes No Yes No Yes No

10 11

12

Check primary main, slow system. Is it okay?

Yes

No

F4-35

CONTINUED

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TROUBLESHOOTING
SYMPTOM 3 CRANKS NORMALLY BUT WON'T START OR HARD START (ENGINE COLD) Air/Fuel mixture too lean • Air leak 2. Poor ignition or misfire 3. Slow fuel cut solenoid valve malfunction 4. Low engine compression 5. Air/Fuel mixture too rich • Choke system malfunction • Loose primary main jet Warning Following troubleshooting flowchart contains fuel system diagnosis and repair procedures. Read following warnings before performing fuel system service: • Fuel vapor Is hazardous. It can easily ignite, causing serious injury and damage. Always keep sparks and flames away from fuel. • Fuel line spills and leaks are dangerous. Fuel can ignite and cause serious injuries or death and damage. Fuel can also irritate skin and eyes. To prevent this, always complete "BEFORE REPAIR PROCEDURE" and "AFTER REPAIR PROCEDURE" described in this manual. ☞ FUEL SYSTEM, BEFORE REPAIR PROCEDURE ☞ FUEL SYSTEM, AFTER REPAIR PROCEDURE RESULTS ACTION Yes Repair or replace appropriate parts. No Yes No Yes No Go to next step. Go to next step. Refer to Section G. Go to next step. If float level is high, check float and needle valve. If level is low, check for clogging between float to needle valve and to fuel pump, and between fuel pump to fuel tank. Check each jet and air bleed for clogging. Go to next step. Go to next step. Repair or replace spark plug. Go to Step 9. Go to next step. Adjust ignition timing. Check both distributor and timing belt. Go to next step. Repair or replace choke system. Go to Step 11. Go to next step. Repair or replace wiring harness between slow fuel cut solenoid valve and carburetor. Repair or replace slow fuel cut solenoid valve. Go to Step 13. Go to next step. Check pistons and cylinders for wear. Check for the following: • Burnt valve • Worn piston, piston ring, or cylinder • Damaged cylinder gasket 1.

POSSIBLE CAUSE

STEP INSPECTION 1 Check if there is any air leakage. Is there any? 2 Disconnect high-tension lead at idle, then check engine speed, Does it decrease equally at each cylinder? Check float level. Is it okay?

3

4 5 6 7 8 9 10

Open and close throttle valve 2-3 times. Does engine start? Check each spark plug. Are they okay? Check ignition timing at idle. Is it okay? Perform ignition timing adjustment. Can timing be adjusted? Check choke system. Is it okay? Check slow fuel cut solenoid. Is it okay? Shake carburetor's connector (6-pin) with ignition switch at ON. Is a "click" sound heard? Check compression pressure. Is it okay? Add oil through plug hole. Does engine start?

Yes No Yes No Yes No Yes No Yes No Yes No Yes No

11 12

Yes No Yes No

F4-36

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TROUBLESHOOTING
STEP 13 INSPECTION Check primary main, slow system. Is it okay? RESULTS Yes Check for the following: • Fuel filter (clogging) • Float room (dust) • Fuel hose (clogging) • Fuel tank (dust) Clean or replace each jet and air bleed. ACTION

No SYMPTOM 4

POSSIBLE CAUSE

CRANKS NORMALLY BUT WON'T START OR HARD START (ENGINE WARM) 1. Percolation • Air vent solenoid valve malfunction 2. Air/Fuel mixture too rich • High float level • Choke system malfunction Warning Following troubleshooting flowchart contains fuel system diagnosis and repair procedures. Read following warnings before performing fuel system service: • Fuel vapor is hazardous. It can easily ignite, causing serious injury and damage. Always keep sparks and flames away from fuel. • Fuel line spills and leaks are dangerous. Fuel can ignite and cause serious injuries or death and damage. Fuel can also irritate skin and eyes. To prevent this, always complete "BEFORE REPAIR PROCEDURE" and "AFTER REPAIR PROCEDURE" described in this manual. ☞ FUEL SYSTEM, BEFORE REPAIR PROCEDURE ☞ FUEL SYSTEM, AFTER REPAIR PROCEDURE RESULTS Yes Repair or replace No Yes No Yes No Yes Go to next step. Go to next step. Repair or replace choke system. Go to next step. Replace air vent solenoid valve. Check for the following: • Fuel filter (clogging) • Float room (dust) • Fuel hose (clogging) • Fuel tank (dust) Inspect both float and needle valve. ACTION

STEP INSPECTION 1 Inspect spark plugs. Are spark plugs wet or covered with carbon? 2 3 4 Check choke system. Is it okay? Check air vent solenoid valve. Is it okay? Check float level? Is it okay? (float level is high.)

No

CONTINUED

F4-37

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TROUBLESHOOTING
SYMPTOM 5 ROUGH IDLE/ENGINE STALLS AT IDLE (ALWAYS) Air/Fuel mixture too rich • High float level • Loose primary main jet • Restricted primary slow air bleed 2. Poor ignition or misfire 3. Air/Fuel mixture too lean • Air leakage • Restricted primary main jet 4. Low engine compression Warning Following troubleshooting flowchart contains fuel system diagnosis and repair procedures. Read following warnings before performing fuel system service: • Fuel vapor is hazardous. It can easily ignite, causing serious injury and damage. Always keep sparks and flames away from fuel. • Fuel line spills and leaks are dangerous. Fuel can ignite and cause serious injuries or death and damage. Fuel can also irritate skin and eyes. To prevent this, always complete "BEFORE REPAIR PROCEDURE" and "AFTER REPAIR PROCEDURE" described In this manual. ☞ FUEL SYSTEM, BEFORE REPAIR PROCEDURE ☞ FUEL SYSTEM, AFTER REPAIR PROCEDURE RESULTS ACTION Yes Repair or replace appropriate parts. No Yes No Yes No Yes No Yes No Yes No Yes No Yes No Yes No Yes No Go to next step. Go to next step. Refer to Section G. Go to next step. Repair or adjust system. Go to Step 6. Go to next step. Adjust ignition timing. Check both distributor and timing belt. Go to Step 8. Go to next step. Adjust idling speed. Adjust or inspect idling mixture. Go to next step. Repair or replace pcv valve. Go to Step 11. Go to next step. Check pistons and cylinders for wear. Check for the following: • Burnt valve • Worn piston, piston ring, or cylinder • Damaged cylinder gasket Check for the following: • Fuel filter (clogging) • Float room (dust) • Fuel hose (clogging) • Fuel tank (dust) Clean or replace each jet and air bleed. 1.

POSSIBLE CAUSE

STEP INSPECTION 1 Check if there is any air leakage. Is there any? 2 Disconnect high-tension lead at idle, then check engine speed. Does it decrease equally at each cylinder? Check idle-up system. Is it okay? Check ignition timing at idle. Is it okay? Perform ignition timing adjustment. Can timing be adjusted? Check idling speed. Is it okay? Perform idling speed adjustment. Can idling speed be adjusted? Check pcv valve. Is it okay? Check compression pressure? Is it okay? Drive vehicle. Does engine stop at takeoff?

3 4 5 6 7 8 9 10

11

Check primary main, slow system. Is it okay?

Yes

No

CONTINUED F4-38

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TROUBLESHOOTING
SYMPTOM 6 ROUGH IDLE/ENGINE STALLS AT IDLE (ENGINE COLD) Choke system malfunction • Warning Following troubleshooting flowchart contains fuel system diagnosis and repair procedures. Read following warnings before performing fuel system service: • Fuel vapor is hazardous. It can easily ignite, causing serious injury and damage. Always keep sparks and flames away from fuel. • Fuel line spills and leaks are dangerous. Fuel can ignite and cause serious injuries or death and damage. Fuel can also irritate skin and eyes. To prevent this, always complete "BEFORE REPAIR PROCEDURE" and "AFTER REPAIR PROCEDURE" described in this manual. ☞ FUEL SYSTEM, BEFORE REPAIR PROCEDURE ☞ FUEL SYSTEM, AFTER REPAIR PROCEDURE INSPECTION Check choke system (quick release). Is it okay? RESULTS Yes Check for the following: • Fuel filter (clogging) • Float room (dust) • Fuel hose (clogging) • Fuel tank (dust) Repair or replace choke system. ACTION

POSSIBLE CAUSE

STEP 1

No SYMPTOM 7

ROUGH IDLE/ENGINE STALLS AT IDLE (ENGINE WARM) 1. Choke system malfunction 2. Float level incorrect 3. Air vent solenoid valve malfunction Warning Following troubleshooting flowchart contains fuel system diagnosis and repair procedures. Read following warnings before performing fuel system service: • Fuel vapor is hazardous. It can easily ignite, causing serious injury and damage. Always keep sparks and flames away from fuel. • Fuel line spills and leaks are dangerous. Fuel can ignite and cause serious injuries or death and damage. Fuel can also irritate skin and eyes. To prevent this, always complete "BEFORE REPAIR PROCEDURE" and "AFTER REPAIR PROCEDURE" described in this manual. ☞ FUEL SYSTEM, BEFORE REPAIR PROCEDURE ☞ FUEL SYSTEM, AFTER REPAIR PROCEDURE RESULTS Yes Go to next step. No Yes No Yes No Yes No Yes ACTION

POSSIBLE CAUSE

STEP INSPECTION 1 Start and warm engine. Check choke valve. Is it fully open? 2 3 4 5 Inspect spark plugs. re spark plugs wet or covered with carbon? Check air vent solenoid valve. Is it okay? Check fuel check valve. Is it okay? Check float level. Is it okay? (float level is high.)

Repair or replace choke system. Repair or replace spark plugs. Go to next step. Go to next step. Replace valve. Go to next step. Repair or replace valve. Check for the following: • Fuel filter (clogging) • Float room (dust) • Fuel hose (clogging) • Fuel tank (dust) Inspect both float and needle valve.

No

F4-39

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TROUBLESHOOTING
SYMPTOM 8 ROUGH IDLE/ENGINE STALLS AT IDLE - WHEN A/C OR P/S ON (IF EQUIPPED Idle-up system malfunction • Solenoid valve malfunction Warning Following troubleshooting flowchart contains fuel system diagnosis and repair procedures. Read following warnings before performing fuel system service: • Fuel vapor is hazardous. It can easily ignite, causing serious Injury and damage. Always keep sparks and flames away from fuel. • Fuel line spills and leaks are dangerous. Fuel can ignite and cause serious injuries or death and damage. Fuel can also irritate skin and eyes. To prevent this, always complete "BEFORE REPAIR PROCEDURE" and "AFTER REPAIR PROCEDURE" described in this manual. ☞ FUEL SYSTEM, BEFORE REPAIR PROCEDURE ☞ FUEL SYSTEM, AFTER REPAIR PROCEDURE INSPECTION Inspect idle-up system. Is it okay? RESULTS Yes No SYMPTOM 9 ENGINE SUDDERLY STALLS OFTEN 1. Disconnected starter connector 2. Poor connection of starter connector Warning Following troubleshooting flowchart contains fuel system diagnosis and repair procedures. Read following warnings before performing fuel system service: • Fuel vapor Is hazardous. It can easily ignite, causing serious injury and damage. Always keep sparks and flames away from fuel. • Fuel line spills and leaks are dangerous. Fuel can ignite and cause serious injuries or death and damage. Fuel can also irritate skin and eyes. To prevent this, always complete "BEFORE REPAIR PROCEDURE" and "AFTER REPAIR PROCEDURE" described in this manual. ☞ FUEL SYSTEM, BEFORE REPAIR PROCEDURE ☞ FUEL SYSTEM, AFTER REPAIR PROCEDURE RESULTS Yes Go to next step. No Yes ACTION ACTION Follow steps for troubleshooting item "Rough idle/engine stalls at idle (Always)". Adjust or repair system, 1.

POSSIBLE CAUSE

STEP 1

POSSIBLE CAUSE

STEP INSPECTION 1 Check starter connector. Is it disconnected or is it not properly connected? 2 Check slow fuel cut valve. Is it okay?

Properly connect connector, or repair or replace if necessary. Check for the following: • Fuel filter (clogging) • Float room (dust) • Fuel hose (clogging) • Fuel tank (dust) Go to next step. Repair or replace wiring harness between slow fuel cut solenoid valve and carburetor. Repair or replace slow fuel cut solenoid valve.

No 3 Shake carburetor's connector (6-pin) with ignition switch at ON. Is a "click" sound heard? Yes No

CONTINUED

F4-40

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TROUBLESHOOTING
SYMPTOM 10 HIGH IDLE SPEED AFTER WARM-UP • Idle-up system malfunction • Choke system malfunction Warning Following troubleshooting flowchart contains fuel system diagnosis and repair procedures. Read following warnings before performing fuel system service: • Fuel vapor is hazardous. It can easily ignite, causing serious injury and damage. Always keep sparks and flames away from fuel. • Fuel line spills and leaks are dangerous. Fuel can ignite and cause serious injuries or death and damage. Fuel can also irritate skin and eyes. To prevent this, always complete "BEFORE REPAIR PROCEDURE" and "AFTER REPAIR PROCEDURE" described in this manual. ☞ FUEL SYSTEM, BEFORE REPAIR PROCEDURE ☞ FUEL SYSTEM, AFTER REPAIR PROCEDURE RESULTS Yes Go to next step. No Yes No Yes No Yes Go to next step. Adjust or repair. Go to next step. Repair or inspect secondary diaphragm link. Check for the following: • Fuel filter (clogging) • Float room (dust) • Fuel hose (clogging) • Fuel tank (dust) Inspect both float and needle valve. ACTION

POSSIBLE CAUSE

STEP INSPECTION 1 Check throttle wiring. Is there sufficient slack in wiring? 2 3 4 Check idle-up system. Is it okay? Check secondary throttle valve. Is it closed? Check float level. Is it okay? (float level is high.)

Adjust or repair accelerator cable.

No SYMPTOM 11

POSSIBLE CAUSE

ENGINE STALLS AT DRIVE AWAY • Restricted primary main system • Accelerator pump malfunction • Poor ignition or misfire • Malfunctioning unloader system Warning Following troubleshooting flowchart contains fuel system diagnosis and repair procedures. Read following warnings before performing fuel system service: • Fuel vapor is hazardous. It can easily ignite, causing serious injury and damage. Always keep sparks and flames away from fuel. • Fuel line spills and leaks are dangerous. Fuel can ignite and cause serious injuries or death and damage. Fuel can also irritate skin and eyes. To prevent this, always complete "BEFORE REPAIR PROCEDURE" and "AFTER REPAIR PROCEDURE" described in this manual. ☞ FUEL SYSTEM, BEFORE REPAIR PROCEDURE ☞ FUEL SYSTEM, AFTER REPAIR PROCEDURE RESULTS ACTION Yes Repair or replace parts as necessary. No Yes No Yes No Yes No Yes No Go to next step. Go to next step. Adjust or repair accelerator cable. Go to next step. Repair or replace accelerator pump. Go to next step. Replace distributor vacuum control unit. Go to next step. Repair or replace unloader system.

STEP INSPECTION 1 Check system for air leakage. Is there any? 2 3 Check throttle wiring. Is there sufficient slack in wiring? Check accelerator pump. Is fuel pumped out when accelerator pump is depressed? Check distributor's vacuum advance. Is it correct? Check unloader system. Is it okay?

4 5

F4-41

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TROUBLESHOOTING
STEP 6 INSPECTION Check primary main, slow system. Is it okay? RESULTS Yes ACTION Check for the following: • Fuel filter (clogging) • Float room (dust) • Fuel hose (clogging) • Fuel tank (dust) Clean or replace each Jet and air bleed.

No SYMPTOM 12 ENGINE STALLS ON DECELERATION

POSSIBLE CAUSE

Slow fuel cut solenoid valve malfunction • Throttle positioner (T/P) malfunction (GULF only) • Warning Following troubleshooting flowchart contains fuel system diagnosis and repair procedures. Read following warnings before performing fuel system service: • Fuel vapor is hazardous. It can easily ignite, causing serious injury and damage. Always keep sparks and flames away from fuel. • Fuel line spills and leaks are dangerous. Fuel can ignite and cause serious injuries or death and damage. Fuel can also irritate skin and eyes. To prevent this, always complete "BEFORE REPAIR PROCEDURE" and "AFTER REPAIR PROCEDURE" described in this manual. ☞ FUEL SYSTEM, BEFORE REPAIR PROCEDURE ☞ FUEL SYSTEM, AFTER REPAIR PROCEDURE RESULTS Yes No Yes No Yes No Yes ACTION Go to next step. Repair or replace any parts as necessary. Go to Step 4. Go to next step. Repair or replace wiring harness between slow fuel cut solenoid valve and carburetor. Repair or replace slow fuel cut solenoid valve. Check for the following: • Fuel filter (clogging) • Float room (dust) • Fuel hose (clogging) • Fuel tank (dust) Adjust dashpot.

STEP INSPECTION 1 Check idle-up system. Is it okay? 2 3 Check slow fuel cut valve. Is it okay? Shake carburetor's connector (6-pin) with ignition switch at ON. Is a "click" sound heard? Check dashpot's touch speed. Is it correct?

4

No SYMPTOM 13 HESITATION

POSSIBLE CAUSE

Spark advance control malfunction • Restricted jets • Air leakage • Warning Following troubleshooting flowchart contains fuel system diagnosis and repair procedures. Read following warnings before performing fuel system service: • Fuel vapor is hazardous. It can easily ignite, causing serious injury and damage. Always keep sparks and flames away from fuel. • Fuel line spills and leaks are dangerous. Fuel can ignite and cause serious injuries or death and damage. Fuel can also irritate skin and eyes. To prevent this, always complete "BEFORE REPAIR PROCEDURE" and "AFTER REPAIR PROCEDURE" described in this manual. ☞ FUEL SYSTEM, BEFORE REPAIR PROCEDURE ☞ FUEL SYSTEM, AFTER REPAIR PROCEDURE RESULTS ACTION Yes Repair or replace any parts as necessary. No Go to next step. Yes No Go to next step. Adjust or repair accelerator cable.

STEP 1 2

INSPECTION Check system for air leakage. Is there any? Check throttle wiring. Is there sufficient slack in wiring?

CONTINUED F4-42

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TROUBLESHOOTING
STEP 3 INSPECTION Check centrifugal spark advance control. Is it okay? RESULTS Yes No Go to next step. Check for the following: • Over advance (Inspect for governor spring damage.) • Under advance (Inspect governor weight, cam op eration.) Go to next step. Repair or replace pump. Go to next step. Replace secondary diaphragm. Go to next step. Clean or replace spark plugs. Go to next step. Repair or replace any parts as necessary. Check for the following: • Fuel filter (clogging) • Float room (dust) • Fuel hose (clogging) • Fuel tank (dust) Clean or replace jets. Note • Dirt and grime can be removed from jets by covering the air horn with your hand. ACTION

4

Check accelerator pump. Is fuel pumped out when accelerator pump is depressed? Check secondary diaphragm. Is it okay? Inspect spark plugs? Are they okay? Is linkage of primary and secondary valve smooth? Inspect every jet. Are they okay?

Yes No Yes No Yes No Yes No Yes

5 6 7 8

No

SYMPTOM 14

POOR ACCELERATION 1. 2. 3. Spark advance control malfunction Restricted intake/exhaust system Air/Fuel mixture too lean • Low float level • Restricted jets, air bleeds • Accelerator pump malfunction 4. Secondary diaphragm malfunction • RPM limiter malfunction 5. Low engine compression 6. Poor ignition Warning Following troubleshooting flowchart contains fuel system diagnosis and repair procedures. Read following warnings before performing fuel system service: • Fuel vapor is hazardous. It can easily ignite, causing serious injury and damage. Always keep sparks and flames away from fuel. • Fuel line spills and leaks are dangerous. Fuel can ignite and cause serious injuries or death and damage. Fuel can also irritate skin and eyes. To prevent this, always complete "BEFORE REPAIR PROCEDURE" and "AFTER REPAIR PROCEDURE" described in this manual. ☞ FUEL SYSTEM, BEFORE REPAIR PROCEDURE ☞ FUEL SYSTEM, AFTER REPAIR PROCEDURE INSPECTION RESULTS Yes No Yes No Yes No Yes No Go to next step. Adjust or repair accelerator cable. Go to next step. Repair or replace intake system. Go to next step. Repair or replace choke system. Go to next step. Repair or replace distributor. ACTION

POSSIBLE CAUSE

STEP 1 2 3 4

Check throttle wiring. Is there sufficient slack in wiring? Inspect intake system. Is it restricted? (especially air cleaner) Check choke valve. Is it fully open after warm-up? Check distributor, (centrifugal spark advance, vacuum spark advance) It is okay?

F4-43

CONTINUED

check for clogging between float to needle valve and to fuel pump.CHAPTER. Check the following: • Cylinder heads.REPAIR MANUAL PAGES. causing serious injury and damage. rings. • Fuel line spills and leaks are dangerous. It can easily ignite. Is it restricted? (especially air cleaner) 3 4 5 Yes No Yes No Yes No CONTINUED F4-44 . Fuel can also irritate skin and eyes. Repair or replace exhaust system. Repair or replace choke valve. Go to next step. check float and needle valve. Check pistons. Is there blockage? Yes No SYMPTOM 15 POSSIBLE CAUSE NO POWER. Replace secondary diaphragm. Does engine start? Yes No Yes No Yes No Yes No 12 Inspect all jets and air bleeds (including high speed richer) of both primary and secondary main passage. ACTION STEP 1 2 Check system for air leakage. Stop vehicle and let it idle to cool engine. Inspect coolant and engine oil. Go to next step. Go to next step. Go to next step. Go to next step. Is it okay? Inspect accelerator pump. It is okay? Check float level. Adjust or repair accelerator cable. Are they okay? Check secondary diaphragm. Go to next step.DRFT. slow system • Centrifugal spark advance malfunction • Restricted exhaust system • Restricted air cleaner Warning Following troubleshooting flowchart contains fuel system diagnosis and repair procedures. Is it okay? RESULTS Yes No Yes No Yes No Go to next step. ☞ FUEL SYSTEM. Clean or replace spark plugs. and cylinders for wear. Is it fully open after warm-up? Check intake system. Is it okay? Add oil through plug hole. Go to next step. Go to next step. gaskets • Valve clearance Clean or replace each jet and air bleed. Check for the following: • Fuel filter (clogging) • Float room (dust) • Fuel hose (clogging) • Fuel tank (dust) ACTION 8 9 10 11 Inspect spark plugs.INDEX TROUBLESHOOTING STEP 5 6 7 INSPECTION Inspect exhaust system.INDEX RANG. Is there any Check engine.TO. FROM.BACK. Does it seem to be overheating? Check throttle wiring. Is there sufficient slack in wiring? Check choke valve. Fuel can Ignite and cause serious Injuries or death and damage. and between fuel pump to fuel tank. FASTEST SPEED IS LOW • Restricted primary main. MANUAL TO. Go to Step 12. Repair or replace any part as necessary. Is it okay? Check compression pressure. always complete "BEFORE REPAIR PROCEDURE" and "AFTER REPAIR PROCEDURE" described in this manual. To prevent this. Always keep sparks and flames away from fuel. Repair or replace accelerator pump. If float level is high. MODEL . BEFORE REPAIR PROCEDURE ☞ FUEL SYSTEM. Go to next step. If level is low. Read following warnings before performing fuel system service: • Fuel vapor is hazardous. AFTER REPAIR PROCEDURE INSPECTION RESULTS Yes No Yes No Go to next step. Repair or replace intake system.

Is it okay? Check centrifugal spark advance control. Is it okay? Yes No Yes No Yes No 11 12 Check compression pressure. Check for the following: • Burnt valve • Worn piston.REPAIR MANUAL PAGES. Go to next step. Go to next step. MODEL . Clean or replace spark plugs.BACK. Replace secondary diaphragm. If level is low. Is it okay? Yes No CONTINUED F4-45 .DRFT. or cylinder • Damaged cylinder gasket Go to next step. Is it restricted? Check float level.INDEX RANG. FROM. Check the following: • Main jet • Air bleed Note • Dirt and grime can be removed from jets by covering the air horn with your hand. Is it okay? (float level is low. Is it okay? Yes No 14 Check main (secondary) system. ACTION 8 9 10 Inspect spark plugs. Repair or replace exhaust system. cam op• eration.) • Under advance (Inspect governor weight. piston ring. MANUAL TO.CHAPTER. and between fuel pump to fuel tank. Are they okay? Check secondary diaphragm. Go to next step. Does engine start? Yes No Yes No 13 Check main (primary) system. Go to next step. Check for the following: Over advance (Inspect for governor spring damage.INDEX TROUBLESHOOTING STEP 6 7 INSPECTION Check exhaust system. check for clogging between float to needle valve and to fuel pump. Is it okay? Add oil through plug hole.) RESULTS Yes No Yes No Go to next step. Go to next step.TO. Check for the following: • Fuel filter (clogging) • Float room (dust) • Fuel hose (clogging) • Fuel tank (dust) Check the following: • Main jet • Air bleed Note • Dirt and grime can be removed from jets by covering the air horn with your hand. Check pistons and cylinders for wear.) Go to Step 13.

BEFORE REPAIR PROCEDURE ☞ FUEL SYSTEM. Check for the following: • Fuel filter (clogging) • Float room (dust) • Fuel hose (clogging) • Fuel tank (dust) 4 5 No Clean or replace jets. always complete "BEFORE REPAIR PROCEDURE" and "AFTER REPAIR PROCEDURE" described in this manual.DRFT. (centrifugal spark advance. AFTER REPAIR PROCEDURE STEP 1 INSPECTION Check engine Does it seem to be overheating? Inspect spark plugs.INDEX RANG. Adjust ignition timing. To prevent this. Read following warnings before performing fuel system service: POSSIBLE • Fuel vapor is hazardous. CAUSE Always keep sparks and flames away from fuel. Fuel can also irritate skin and eyes. MANUAL TO. • Fuel line spills and leaks are dangerous. Are they okay? RESULTS Yes No Yes No Yes No Yes No Yes ACTION Go to Step 3.BACK. Inspect coolant and engine oil. Is it okay? 2 3 Perform ignition timing adjustment. Replace fuel. Is it okay? Inspect every jet. MODEL . Fuel can also irritate skin and eyes. Air/Fuel mixture too lean • Restricted primary main. Check both distributor and timing belt. always complete "BEFORE REPAIR PROCEDURE" and "AFTER REPAIR PROCEDURE" described in this manual.CHAPTER. slow system • Poor ignition or misfire • Insufficient engine coolant Warning Following troubleshooting flowchart contains fuel system diagnosis and repair procedures. Repair or replace thermostat. FROM. Repair or replace distributor.REPAIR MANUAL PAGES. causing serious injury and damage. SYMPTOM 17 AFTERBURN OCCURS DURING DECELERATION • Poor ignition or misfire • Slow fuel cut solenoid valve malfunction • Throttle position (T/P) malfunction (GULF only) • Dashpot malfunction Warning Following troubleshooting flowchart contains fuel system diagnosis and repair procedures. Read following warnings before performing fuel system service: POSSIBLE • Fuel vapor is hazardous. ☞ FUEL SYSTEM.INDEX TROUBLESHOOTING SYMPTOM 16 KNOCKING 1. To prevent this. Go to next step. CONTINUED F4-46 .TO. BEFORE REPAIR PROCEDURE ☞ FUEL SYSTEM. It can easily ignite. ☞ FUEL SYSTEM. Fuel can ignite and cause serious Injuries or death and damage. causing serious injury and damage. Always keep CAUSE sparks and flames away from fuel. AFTER REPAIR PROCEDURE STEP INSPECTION 1 Check ignition timing at idle. Go to next step. Go to next step. It can easily ignite. Clean or replace spark plugs. Can timing be adjusted? Inspect distributor. • Fuel line spills and leaks are dangerous. Go to next step. Are spark plugs electrode free of carbon accumulation? RESULTS Yes No 2 Yes No ACTION Stop vehicle and let it idle to cool engine. Fuel can ignite and cause serious injuries or death and damage. vacuum spark advance) It is okay? Check thermostat.

• Fuel line spills and leaks are dangerous. Go to Step 4. Go to next step. Is it correct? Perform idling speed adjustment. Is it fully open after warm-up? Check float level. Is it normal? Add oil through plug hole. FROM. Is it okay? (float level is high. Always keep sparks and flames away from fuel. Adjust CO and HC concentrations. Adjust or repair any part as necessary. Adjust ignition timing.DRFT. Repair or replace any part as necessary. Read following warnings before performing fuel system service: • Fuel vapor is hazardous. Check the following: • Float • Needle valve Go to next step. Check pistons and cylinders for wear. vacuum spark advance) Is it okay? Check compression pressure. ☞ FUEL SYSTEM. Fuel can ignite and cause serious injuries or death and damage. AFTER REPAIR PROCEDURE INSPECTION Check system for air leakage. causing serious injury and damage.BACK. Repair or replace choke system. Is it okay? Shake carburetor's connector (6-pin) with ignition switch at ON. ACTION POSSIBLE CAUSE STEP 1 2 3 4 5 6 7 8 9 10 11 Check distributor. Fuel can also irritate skin and eyes. Repair or replace slow fuel cut solenoid valve.INDEX TROUBLESHOOTING SYMPTOM 18 POOR FUEL ECONOMY • Incorrect adjustment of main adjust screw • Incorrect adjustment of idle speed • High float level • Poor ignition or misfire Warning Following troubleshooting flowchart contains fuel system diagnosis and repair procedures. Is a "click" sound heard? Check both CO and HC concentration. (centrifugal spark advance. Repair or replace wiring harness between slow fuel cut solenoid valve and carburetor. Check for the following: • Burnt valve • Worn piston. Go to next step. Repair or replace distributor. piston ring. Go to Step 8. MANUAL TO. Does engine start? Yes No Yes No Yes No 12 13 14 Is main jet loose? Yes No F4-47 CONTINUED . always complete "BEFORE REPAIR PROCEDURE" and "AFTER REPAIR PROCEDURE" described in this manual. Is it okay? Perform ignition timing adjustment. Can it be adjusted? Check slow fuel cut solenoid valve. BEFORE REPAIR PROCEDURE ☞ FUEL SYSTEM. Can timing be adjusted? Check idling speed. Go to next step. or cylinder • Damaged cylinder gasket Check for the following: • Fuel filter (clogging) • Float room (dust) • Fuel hose (clogging) • Fuel tank (dust) Clean or replace jets. It can easily ignite. To prevent this. Go to Step 14.TO.REPAIR MANUAL PAGES. Go to next step. MODEL .INDEX RANG. Go to next step. Are they okay? Check choke valve.CHAPTER. Is there any? Check ignition timing at idle. Go to next step. Check both distributor and timing belt. Go to next step. Go to Step 6. Adjust idling speed.) RESULTS Yes No Yes No Yes No Yes No Yes No Yes No Yes No Yes No Yes No Yes No Go to next step.

. G–5/6 G–6/7 G–8 G–9 G–9 G–10 G–10 G–10/11 CHARGING SYSTEM BATTERY REMOVAL/INSTALLATION 1. . .INDEX RANG. . . . .REPAIR MANUAL PAGES.INDEX ENGINE ELECTRICAL SYSTEM CHARGING SYSTEM . . . . . . . . . . . . . G– 1 G– 1 G– 1/2 G– 2 G– 2/3 G– 3/4 G– 5 G– 5 G– 5 IGNITION COIL INSPECTION . . . . . . . . . . . . . . Go to next step. . . . . . 2. Go to next step. .5—4.9 {35—50. . .4 V Yes Action Go to Step 3. . . . . . . . . . . .4 V Below 12. . . . FROM. . . . . . . . . . . Apply test load (see test load chart) to battery using a battery y load tester and record battery voltage after 15 seconds. BATTERY REMOVAL/INSTALLATION . . . .TO. . STARTER REMOVAL/INSTALLATION . . . . . . GENERATOR INSPECTION . . IGNITER INSPECTION . . . DISTRIBUTOR INSPECTION (F2 CARB) .DRFT. . . . . . . . . . . . . . . . . . . . Replace battery. .BACK. . . Is voltage more than specification? 3 No CONTINUED G–1 . . . HIGH-TENSION LEAD REMOVAL/INSTALLATION . 31—43} FRONT 75D26R FRONT N·m {kgf·cm. . Step Inspection Measure open circuit voltage of battery. . . . . BATTERY INSPECTION . . . . Above 12.4 V Below 12. . . . 3. in·lbf} 1 2 3 4 5 Negative battery cable Positive battery cable Battery clamp + Installation Note (RH) Battery Battery tray BATTERY INSPECTION Battery ST D Inspect the battery in the following procedure. . . . . . . . . . Battery Clamp Installation Note (RH) D Install the battery clamp as shown. . . . . . Battery is okay. BATTERY RECHARGING . . . STARTING SYSTEM . . . IGNITION SYSTEM . . Install in the reverse order of removal. . Remove in the order indicated in the table. . STARTER INSPECTION . . . . . MANUAL TO. . . . . . . . IGNITION COIL REMOVAL/INSTALLATION . . . . . . . . . . . . 1 2 Quick charge for 30 minutes and recheck voltage. . . .4 V Above 12. . . . . Replace battery. .MAIN. . . . . . . MODEL . . . DISTRIBUTOR DISASSEMBLY/ASSEMBLY . . . . . . . DISTRIBUTOR REMOVAL/INSTALLATION . . . . . . . . . GENERATOR REMOVAL/INSTALLATION . . . .

Install in the reverse order of removal. Disconnect the negative battery cable. measure the battery positive voltage and verify that the battery keeps specified voltage for more than 1 hour. Disconnect the negative battery cable. MODEL .5 2.6 9. 2. Remove in the order indicated in the table. Place a battery in a pan of water to prevent it from overheating. remove the battery plugs while charging the battery. MANUAL TO. Verify that the ignition switch (engine switch) is at the OFF position and that the key has been removed. Battery positive voltage with load Approximate battery temp. Measure the back-up current between the negative battery terminal and the negative battery cable.1 8. Always disconnect the battery before performing the following operation.REPAIR MANUAL PAGES. 4. 5. replace the battery. D Do not quick charge for over 30 minutes.4 9.0 4. touching the vehicle body with generator terminal B will generate sparks. and damage to the electrical components. The water level should come up about halfway on the battery. Inspect the drive belt deflection/tension. remove the fuse in the main fuse block and the fuse block one by one while measuring the back-up current. Remove the fresh-air duct. 2.7 8.4 V 5. Adjust the charging current as follows.0—4.DRFT. 1.5 5. FROM.5 9.5—5. Back-up current 20 mA max. 4. Battery type (5–hour rate) 34B19R (27) 55D23R (48) 75D26L (52) 75D26R (52) 80D26R (55) 95D31R (64) Slow charge (A) 3. 4. If the current exceeds the maximum. 3. WL Turbo) 3. 5.5—6. DRIVE BELT. air intake pipe and air hose.5 6. 3. Keep water off the top of the battery.5—6.0 Quick charge (A)/(30 min. Inspect and repair harnesses and connectors of the fuse at which the current reduces.9 8. Specification Above 12. D To avoid deformation or damage to the battery. Connect a battery charger to the battery. 21 °C {70 °F} 15 °C {60 °F} 10 °C {50 °F} 4 °C {40 °F} – 1 °C {30 °F} – 7 °C {20 °F} –12 °C {10 °F} –18 °C { 0 °F} Minimum voltage(V) 9. After the battery has been recharged.CHAPTER. If not as specified. GENERATOR REMOVAL/INSTALLATION Warning D When the battery cables are connected.) CONTINUED G–2 .5—8.INDEX CHARGING SYSTEM Test load chart Battery 34B19R 55D23R 75D26L 75D26R 80D26R 95D31R Load (A) 110 180 195 195 195 250 BATTERY 1. Caution D Operating electrical loads while measuring the back-up current can damage the circuit tester. BATTERY RECHARGING Caution D When disconnecting the battery.5 5.INDEX RANG.5—6.5 5.3 9.TO.) 20 30 35 35 35 40 Back-up Current 1.BACK. (WL. This can cause personal injury. It will damage the battery. remove the negative cable first and install it last to prevent damage to electrical components or the battery. (Refer to Section B2. DRIVE BELT INSPECTION. fire.

ft·lbf} N·m {kgf·m.TO. WL Turbo).8 N·m {50—70 kgf·cm.8—5. MODEL . (Refer to Section B2.REPAIR MANUAL PAGES.0—3.3. Verify that the drive belt deflection/tension is correct. 28—38} N·m {kgf·m.0—6.9—2.INDEX CHARGING SYSTEM G6 5.8—5.BACK. 14—18} 38—51 {3. F2 CARB.6—2. 28—38} A 5. 2.8—5.3. DRIVE BELT INSPECTION. I (WL. 15—22} A B C 19—25 {1.CHAPTER. ft·lbf} S L CONTINUED G–3 . WL Turbo 20—30 {2.6.3.8 N·m {50—70 kgf·cm. 4.3. ft·lbf} F2 CARB. 12—16} 1 2 3 4 5 Terminal B wire Connector Drive belt (generator) Generator strap (G6) Generator GENERATOR INSPECTION Generator Warning Light 1. DRIVE BELT. MANUAL TO. FROM.DRFT.1.0—6.INDEX RANG. inspect the generator warning light and wiring harnesses between the battery and generator warning light and between the battery and generator terminal L (G6. 28—38} 38—51 {3. 44—60 in·lbf} WL. F2 CIS 5.3.8 N·m {50—70 kgf·cm. 44—60 in·lbf} B C 38—51 {3. 38—51 {3. If not. F2 CARB.0—6. 44—60 in·lbf} 16—22 {1. Turn the ignition switch (engine switch) on and verify that the generator warning light illuminates.8—5.) 3. F2 CIS). Verify that the battery is fully charged. 28—38} ST G6. F2 CIS N·m {kgf·m.

1—14.CHAPTER.425 13. If not. F2 CIS 14.5 V Engine hot Engine speed (rpm) 1. Verify that the drive belt deflection/tension is correct. Turn all electrical loads off. 2. disassemble and inspect the generator.025—7. F2 CARB. MANUAL TO.DRFT. If not as specified. F2 CARB. D Headlights D Blower motor D Rear window defroster Note D Current required for generating power varies with electrical loads applied. Verify that the drive belt deflection/tension is within the specification.7 Must not be 0 A.INDEX CHARGING SYSTEM Standard voltage Terminal B A S I WL.000—2.05—14. WL Turbo Ignition switch ON (V) G6. 0—74 Standard voltage Terminal B L S WL. If generator terminal B current will not increase. FROM. 5. 5.85 A S I 6. WL Turbo Approx. 0—62 WL. 8. A S I CONTINUED G–4 . 6.7 13. F2 CARB. F2 CIS Current 1. 1 B+ Idle [20°C {68°F}] (V) G6.0 14.BACK. Disconnect the negative battery cable. Verify that the generator warning light goes out after engine starts. (Refer to Section B2.0—14. Verify that the battery is fully charged. Verify that the battery is fully charged. Standard current (Reference) S L Measuring conditions Room temperature: 20 °C {68 °F} Voltage: 13. Start the engine and increase the engine speed to 2. 9. F2 CIS B+ Approx. 0—58 Approx. Generator Voltage 1. DRIVE BELT.05—14. 4. (Refer to Section B2.85 7. DRIVE BELT. disassemble and inspect the generator. Turn the following electrical loads on and verify that the current reading increases. DRIVE BELT INSPECTION.000 *: Terminal B current (A)* G6.00—14.0 Idle (V) [20°C {68°F}] WL.0—4. WL Turbo Engine switch ON (V) WL.1—14. F2 CIS Approx. 2. 4. MODEL . WL Turbo) and the generator.INDEX RANG.85 14. Turn off all electrical loads.REPAIR MANUAL PAGES. between generator terminal B and the wiring harness.) 3. Turn the ignition switch (engine switch) to START position and verify that the generator turns smoothly without any noise while the engine is running. 7. DRIVE BELT INSPECTION. inspect the wiring harness between the S terminals of the generator (WL.TO.) 3. Connect the negative battery cable.000 2. F2 CARB. 0—43 Approx. Connect an ammeter.500 rpm. G6. WL Turbo 14. 5. Measure the voltage at the terminals shown in the table. WL Turbo B+ B+ 0 2. capable of reading 120 A or over. 6.

79—112} 2. (Refer to IGNITION SYSTEM. F2 CARB.5—1. 60.87—9. measure the voltage at terminal C using the voltmeter.BACK. F2 CIS G6. Install in the reverse order of removal. 79—112} 1. replace the igniter. Disconnect the negative battery cable.87—9. in·lbf} F2 CARB 8. 3. 60. While cranking the engine. F2 CIS 1. G6.) IGNITION COIL REMOVAL/INSTALLATION G6. 2. 4. MODEL .5 V 5. Disconnect the igniter connector. MANUAL TO. Remove in the order indicated in the table.8] N·m {kgf·cm. 0.TO.REPAIR MANUAL PAGES.INDEX RANG. Turn the ignition switch on and measure the voltage at connector terminal A using the voltmeter.DRFT. Specification Approx.8—86. 6.9 {20—30.7 {90—130. Turn the ignition switch off and verify that there is continuity between terminal B and the body ground. Disconnect the ignition coil connector. F2 CIS Primary Coil Winding 1.80 {70—100.7 {90—130. 18—26} ST N·m {kgf·cm. F2 CIS 1.INDEX IGNITION SYSTEM IGNITION SYSTEM IGNITER INSPECTION G6.9 {15—20. FROM. CONTINUED G–5 .8—86.80 {70—100. in·lbf} 1 2 3 4 5 6 Center lead Connector Ignition coil bracket Condenser Ignition coil Igniter IGNITION COIL INSPECTION G6. 14—17} Specification Battery positive voltage 3.9—12. IGNITION COIL REMOVAL/INSTALLATION. 2.9—12. If voltage and continuity are okay. F2 CIS 8. F2 CARB.8] 6.CHAPTER.0—2.

(Refer to IGNITION SYSTEM.) DISTRIBUTOR REMOVAL/INSTALLATION G6. Specification 10—16 k [20 °C {68 °F}] 19—25 {1.035—1.6.BACK. If not as specified. Measure the resistance at the primary coil using an ohmmeter. IGNITION COIL REMOVAL/INSTALLATION.) Secondary Coil Winding 1. MANUAL TO.CHAPTER. Disconnect the ignition coil connector. F2 CARB. Disconnect the negative battery cable. Disconnect the center lead. MODEL . 3. replace the ignition coil. (Refer to IGNITION SYSTEM. 2. ENGINE TUNE-UP. Remove in the order indicated in the table. F2 CIS: 0. ft·lbf} CONTINUED G–6 . Specification [20 °C {68 °F}] G6. F2 CIS F2 CARB (+) 4. Install in the reverse order of removal. 14—18} G6.) G6 F2 CARB 3.REPAIR MANUAL PAGES.81—0. Adjust the ignition timing. IGNITION TIMING ADJUSTMENT. 2. If not as specified.INDEX IGNITION SYSTEM 2.DRFT. replace the ignition coil. Measure the resistance at the secondary coil using an ohmmeter. (Refer to Section F2. 3. F2 CIS N·m {kgf·m. IGNITION COIL REMOVAL/INSTALLATION.TO.265 Ω G6. 4. F2 CIS 1. FROM.99 Ω F2 CARB: 1.INDEX RANG.9—2.

DRFT. MODEL .6. FROM.9—2. 14—18} N·m {kgf·m.INDEX IGNITION SYSTEM Distributor Installation Note D Verify that the No. and align the distributor matching marks.CHAPTER. F2 CARB MATCHING MARKS 19—25 {1.9—2.TO.REPAIR MANUAL PAGES. 14—18} N·m {kgf·m.1 cylinder is at top dead center. ft·lbf} F2 CIS 19—25 {1. MANUAL TO.6. ft·lbf} ST 1 2 Vacuum hose High-tension lead + HIGH-TENSION LEAD REMOVAL/INSTALLATION Connector Distributor + Installation Note 3 4 CONTINUED G–7 .BACK.INDEX RANG.

MODEL . Assemble in the reverse order of disassembly. 2.TO.CHAPTER.REPAIR MANUAL PAGES. Disassemble in the order indicated in the table. FROM. F2 CARB.INDEX RANG.DRFT. MANUAL TO.BACK. G6 F2 CIS R R F2 CARB R 1 2 3 4 5 6 7 Cap Rotor Cover Signal rotor Pick-up coil with igniter Vacuum control unit Breaker 8 9 10 11 12 13 Coupling set Governor set Oil seal Bearing Distributor body O-ring CONTINUED G–8 .INDEX IGNITION SYSTEM DISTRIBUTOR DISASSEMBLY/ASSEMBLY G6. F2 CIS 1.

200 " 3. Disconnect the vacuum hose to the vacuum control unit. use the timing light to check the advance angle on crankshaft pulley. ENGINE TUNE-UP. 2. and plug the end of the hose.INDEX IGNITION SYSTEM DISTRIBUTOR INSPECTION (F2 CARB) Centrifugal Spark Advance Control 1. While gradually increasing the engine speed. replace it. 4. MANUAL TO. 5. disassemble and inspect the distributor. MODEL . weak governor spring (if the governor spring is broken.) 3. ST Resistance 900—1. If necessary. the advance will rise very high) (2) Insufficient advance . inHg }) 6. TIMING LIGHT DIAPHRAGM A ( ! ) 11—15 VACUUM HOSE 0—2 0 20 53. Measure the resistance. .9} {400. . FROM. 19—23 (!) 9—13 ADVANCE (DEGREE) VACUUM ( kPa { mmHg .200 6. Warm up the engine to the normal operating temperature.REPAIR MANUAL PAGES.INDEX RANG. HIGH-TENSION LEAD REMOVAL/INSTALLATION Caution D The high-tension leads must be reinstalled to their original positions. and plug the end of the hose. Vacuum Spark Advance Control 1. Turn off all electrical loads. Warm up the engine to normal operating temperature. 15.7} 5. 5. Turn off all electrical loads.3 {150. Attach a vacuum pump to the diaphragm A and check using the timing light while applying vacuum. governor weight or cam malfunction 6.000 ENGINE SPEED ( rpm ) (1) Excess advance . disassemble and inspect the distributor.DRFT. 2. Disconnect the vacuum hose to the vacuum control unit. 2.CHAPTER. Connect an ohmmeter to the pick-up coil.TO. 4.) 3. CONTINUED G–9 . and negatively affect the electronic components. If necessary. (Refer to Section F2.BACK.200 2. Pick-up Coil With Igniter Inspection 1. ENGINE TUNE-UP. Incorrect installation can damage the leads and cause power loss. (Refer to section F2. If it is not within specification. Check to be sure that the idle speed and ignition timing are correct. Check to be sure that the idle speed and ignition timing are correct. 0—2 ADVANCE (DEGREE) 0 1.

7 N·m {100—120 kgf·cm.) 3.7 N·m {100—120 kgf·cm.TO. ft·lbf} 1 2 3 Terminal B wire Terminal S wire Starter STARTER INSPECTION On-vehicle Inspection 1. 87—104 in·lbf} 9. Specification Above 8 V 4. BATTERY REMOVAL/INSTALLATION.8—5. 87—104 in·lbf} 38—51 {3.BACK. Remove in the order indicated in the table. touching the vehicle body with starter terminal B will generate sparks.3. Verify that the battery is fully charged. If not as specified. If the voltage is not as specified.INDEX RANG. 2. (WL. ignition switch (engine switch). Connect the starter. G6. This can cause personal injury. No Load Test 1. 5. measure the voltage at terminals S and B when the ignition switch (engine switch) is at START position.9—11. (G6) 4. Disconnect the negative battery cable.CHAPTER. 28—38} 9. 1. Install in the reverse order of removal. If the voltage is within the specification. FROM.INDEX STARTING SYSTEM STARTING SYSTEM WL. 2. WL Turbo) (Refer to CHARGING SYSTEM. ft·lbf} CONTINUED G–10 . and damage to the electrical components. 2. battery. 3. F2 CIS 38—51 {3.8—5. voltmeter. MODEL . fire.3.REPAIR MANUAL PAGES. and ammeter as shown. Remove the battery. 28—38} N·m {kgf·m. WL Turbo STARTER REMOVAL/INSTALLATION Warning D When the battery cables are connected. Verify that the battery is fully charged. remove the starter and inspect the magnetic switch and the starter. MANUAL TO. F2 CARB.DRFT. inspect the wiring harness. Always disconnect the battery before performing the following operation. A B IGNITION SWITCH (ENGINE SWITCH) M V STARTER BATTERY TERMINAL S N·m {kgf·m.9—11. Crank the engine and verify that the starter turns smoothly without any noise. Remove the intake manifold bracket. 5.

5 Below 100 F2 CARB. Measure the voltage and current while the starter is operating. FROM. Specification Engine type Item Voltage (V) Current (A) G6 11.BACK. Operate the starter and verify that it turns smoothly.5 Below 60 WL. CONTINUED G–11 .TO.REPAIR MANUAL PAGES. MANUAL TO. MODEL .INDEX STARTING SYSTEM 3. 4.INDEX RANG. If not as specified.CHAPTER.DRFT. repair or replace the inner parts as necessary. F2 CIS 11. WL Turbo 11 Below 130 5.

. . . . . . . . . . . . . MODEL . . . . . . . . . . . . . . . . H–11 PILOT BEARING INSPECTION . . . . . CLUTCH PEDAL REMOVAL/ INSTALLATION . . Draw the fluid from the reserve tank with a suction pump. . . . . . . . CLUTCH PEDAL INSPECTION/ ADJUSTMENT . . . . . . .BACK. . . and then tighten the clutch pipe using the SST (49 0259 770B). . . . Slowly pump the clutch pedal several times. H– 8/10 CLUTCH COVER INSPECTION . . . . . remove it using the SST (49 0259 770B). . . . . . . . CLUTCH FLUID CLUTCH FLUID INSPECTION Note D The fluid in the reservoir must be maintained between the MIN/MAX level during replacement. H– 7 CLUTCH RELEASE CYLINDER REMOVAL/INSTALLATION . . . . . . . . . . . . . . . . . . . . . . CLUTCH FLUID INSPECTION . . If removing the clutch pipe. . . . . . . . . . . . . . . . . bleed the air. . . . . . . . . 3. . . . CLUTCH FLUID REPLACEMENT/AIR BLEEDING . . 4. D Do not reuse the clutch fluid that was drained out. . . . . . . . . . . . . . If any clutch pipe has been disconnected any time during the procedure. . . . . . MANUAL TO. . FROM. . . . . . . . . . . H–11 FLYWHEEL . . . . . H–11 GENERAL PROCEDURES Clutch Pipe Removal/Installation 1. . . . . . . . . . . . . . . . . . . . . 1. . Close the bleeder screw using the SST. . . . . . . . CLUTCH FLUID . . . . . . . . . . . . . . CLUTCH MASTER CYLINDER . . . . . CLUTCH MASTER CYLINDER DISASSEMBLY/ASSEMBLY . . . . . . . . . With the clutch pedal depressed. . . H– 7 CLUTCH UNIT . . . . . . . . . . . CLUTCH MASTER CYLINDER REMOVAL/INSTALLATION . . . . . . . . .DRFT. . . . . . . . . . . 5. . 2. . . . . . . . . Place the other end of the vinyl hose into a container. . . . . . . . If this should happen. . . . . H– 7 CLUTCH RELEASE CYLINDER DISASSEMBLY/ASSEMBLY . . . . . . . loosen the bleeder screw using the SST to let fluid escape. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H– 1 H– 1 H– 1 H– 1/2 H– 2 H– 2/3 H– 3 H– 4 H– 5 H– 5 H– 5/6 CLUTCH RELEASE CYLINDER . . . . . H– 8 CLUTCH UNIT REMOVAL/INSTALLATION . . . H–11 CLUTCH RELEASE COLLAR INSPECTION . 2. . wash it off immediately. . CLUTCH FLUID REPLACEMENT/AIR BLEEDING Caution D Clutch fluid will damage painted surfaces. . . .TO. . . . . . . CLUTCH PEDAL . Remove the bleeder cap from the clutch release cylinder and attach a vinyl hose to the bleeder plug. H–11 FLYWHEEL INSPECTION . . . . . . .MAIN. H–10 CLUTCH DISC INSPECTION . . . . . . . . . . . . . . . . . . . . .REPAIR MANUAL PAGES. . . . . . . . . . . . . . . . . . . . BLEEDER SCREW 49 0259 770B CONTINUED H–1 . . . . . . be careful not to spill clutch fluid on a painted surface. . . . . add brake fluid. . . . D Do not mix different brands of clutch fluid. . . . . CLUTCH PEDAL DISASSEMBLY/ ASSEMBLY . . . modify the clutch pipe tightening torque to allow for the use of a torque wrench–SST (49 0259 770B) combination. . . . . . . . . . . . . . . .INDEX RANG. . . . . and inspect for leakage after the procedure has been completed. If installing the clutch pipe. . . . . . . . . . . .INDEX CLUTCH GENERAL PROCEDURES . .

52—78 in·lbf} 3. CLUTCH PEDAL 1.70 in} B A 14—17 {1.6—246.6 mm {9.9—8. Pedal height 241.REPAIR MANUAL PAGES.4—1.INDEX CLUTCH FLUID. CLUTCH PEDAL CLUTCH PEDAL INSPECTION/ADJUSTMENT Clutch Pedal Height 1. 11—13} PEDAL HEIGHT CARPET N·m {kgf·m.Tighten the bleeder screw. 4. adjust the pedal height by turning stopper bolt A and clutch switch (or adjust bolt) B. CONTINUED H–2 . MANUAL TO.Repeat steps 4 and 5 until only clean fluid is seen. 2.DRFT. Measure the distance from the upper surface of the pedal pad to the carpet. ft·lbf} 2.INDEX RANG.8 N·m {60—90 kgf·cm. MODEL .CHAPTER.Check for correct clutch operation.8.52—9.If necessary. FROM.Add fluid to the MAX mark.BACK. Tightening torque 5.TO.

Without depressing the clutch pedal.31 in} CLUTCH PEDAL REMOVAL/INSTALLATION 1. INTAKE-AIR SYSTEM.If the clutch pedal disengagement stroke is outside of the specification. ACCELERATOR PEDAL REMOVAL/INSTALLATION.3} PEDAL FREE PLAY N·m {kgf·m.9—9. D 19—25 {1.INDEX RANG.Install in the reverse order of removal. WL Turbo D Refer to section F2. F2 Carb D Refer to section F2.0 mm {0.H. 2. F2 CIS) Spring pin Clevis pin Nut Clutch pedal component R. and verify the pedal stroke. Disconnect the negative battery cable.9—2.8—5.D.80 N·m {70—100 kgf·cm. adjust the clutch pedal. Standard distance A: 14. ft·lbf} 19—25 {1.Remove in the order indicated in the table.6.12—0.0—8.After installation. Depress the clutch pedal by hand until clutch resistance is felt. 3. MODEL .If necessary.6.5 mm {5.CHAPTER.58—1. 14—18} 2. 14—18} C 12—16 {1.REPAIR MANUAL PAGES. 61—86. and measure the pedal free play. adjust the pedal height and pedal free play.9 in} (reference value) CONTINUED H–3 .INDEX CLUTCH PEDAL Clutch Pedal Free Play 1.8 in·lbf} N·m {kgf·m. ACCELERATOR PEDAL REMOVAL/INSTALLATION.9—2.7. Clutch Release Point Inspection 1.H. FROM. F2 CIS. ft·lbf} 1 2 3 4 5 Clutch switch connector (G6. Pedal free play 3. RELEASE POINT FULL STROKE END POSITION PEDAL STROKE 3.D.6—37.BACK. G6. 2. WL. adjust the pedal free play by turning locknut C and adjusting push rod D. slowly shift the shift lever into reverse position until the gears contact. Pedal stroke 146.TO.47 in} (reference value) A 6.5—151.7—12. MANUAL TO.2—1. (Refer to CLUTCH PEDAL INSPECTION/ADJUSTMENT) L.5 mm {0. INTAKE-AIR SYSTEM. 8.DRFT. 4.Gradually depress the clutch pedal and measure the stroke distance from the point the gear noise stops (release point) up to the full stroke end position.

7—12. Note D Apply lithium-based grease to the spring and bush when assembling.2—1. 8. MANUAL TO.3} 14—17 {1.DRFT. F2 Carb) Nut Stopper rubber Retaining ring Washer Bush Pin Fork Push rod Nut Pedal pad Clutch pedal component CONTINUED H–4 . Disassemble in the order indicated in the table. WL Turbo.CHAPTER. Assemble in the reverse order of disassembly. 12—16 {1. ft·lbf} 1 2 3 4 5 6 7 8 9 10 11 12 13 Clutch switch (G6.INDEX RANG.7. 2. 11—13} R N·m {kgf·m.BACK.4—1.8. MODEL . F2 CIS) Adjustment bolt (WL.REPAIR MANUAL PAGES. FROM.TO.INDEX CLUTCH PEDAL CLUTCH PEDAL DISASSEMBLY/ASSEMBLY 1.

113—190} * 49 0259 770B N·m {kgf·cm. R R R 84—112 N·m {8.5 kgf·m. 6.8—21. Remove in the order indicated in the table.5—11. MANUAL TO.INDEX CLUTCH MASTER CYLINDER CLUTCH MASTER CYLINDER CLUTCH MASTER CYLINDER REMOVAL/INSTALLATION 1.DRFT.REPAIR MANUAL PAGES.TO. Assemble in the reverse order of disassembly.CHAPTER.8 {70—100. 2. 60.INDEX RANG.BACK. in·lbf} 1 2 Clutch pipe Nut 3 4 Clutch master cylinder Gasket CLUTCH MASTER CYLINDER DISASSEMBLY/ASSEMBLY 1.7} R SST * 12.5 {130—220. 61. Disassemble in the order indicated in the table. Install in the reverse order of removal.5—83. MODEL . 2. FROM.8—86.9—9.1 ft·lbf} CONTINUED H–5 .

INDEX RANG. CONTINUED H–6 .TO. Snap Ring Assembly Note D Hold the piston down using a cloth-wrapped pin punch.BACK. FROM.REPAIR MANUAL PAGES. MODEL . MANUAL TO.DRFT.CHAPTER.INDEX CLUTCH MASTER CYLINDER 1 Snap ring + Disassembly Note + Assembly Note Piston Protector Primary cap Return spring Tank cap Reservoir Bushing Joint bolt Gasket One-way valve piston Return spring One way valve pin Clutch master cylinder body 2 3 4 5 6 7 8 9 10 11 12 13 14 Snap Ring Disassembly Note D Hold the piston down using a cloth-wrapped pin punch.

3. ft·lbf} 1 2 E-clip Clutch hose 3 4 Bolt Clutch release cylinder CLUTCH RELEASE CYLINDER DISASSEMBLY/ASSEMBLY 1. MANUAL TO. Assemble in the reverse order of disassembly. 22—26 {2.REPAIR MANUAL PAGES.INDEX RANG.CHAPTER.8 N·m {60—90 kgf·cm. Remove in the order indicated in the table.7. 12—16} (LITHIUM BASED GREASE) N·m {kgf·m.9—8.BACK.2—2. Install in the reverse order of removal. 16—19} 16—22 {1.INDEX CLUTCH RELEASE CYLINDER CLUTCH RELEASE CYLINDER CLUTCH RELEASE CYLINDER REMOVAL/INSTALLATION 1.6—2. 2. FROM.DRFT. G6 R 5.TO. MODEL . 53—78 in·lbf} EXCEPT G6 1 2 3 4 Boot Push rod Piston and cap Return spring 5 6 7 8 Bleeder cap Bleeder screw Steel ball Clutch release cylinder body CONTINUED H–7 . Disassemble in the order indicated in the table. 2.

3} EXCEPT G6 :97—102 {9. 67.8—10. MANUAL TO.BACK. 14—19} SST SST SST (MOLYBDENUM SULFIDE) N·m {kgf·m. MANUAL TRANSMISSION. MANUAL TRANSMISSION.3—10. MANUAL TRANSMISSION REMOVAL/INSTALLATION Clutch release collar Clutch release fork Clutch cover + Removal Note + Installation Note 5 6 Clutch disc + Installation Note Pilot bearing + Removal Note + Installation Note Flywheel + Removal Note + Installation Note 7 CONTINUED H–8 . Remove in the order indicated in the table.REPAIR MANUAL PAGES.7.9—75. 70. FROM.CHAPTER.5. 2. Install in the reverse order of removal.8—2.INDEX RANG.TO.0. MANUAL TRANSMISSION REMOVAL/INSTALLATION + Section J2.INDEX CLUTCH UNIT CLUTCH UNIT CLUTCH UNIT REMOVAL/INSTALLATION 1. MODEL .DRFT. G6 :92—98 {9. ft·lbf} 1 2 3 4 Transmission + Section J1.3—72.9} ENGINE SIDE SST TRANSMISSION SIDE 18—26 {1.

3. 2.DRFT. G6 1 49 SE01 310A 3 5 7 4 6 49 E011 1A0 8 2 Pilot Bearing Removal Note Note D The pilot bearing does not need to be removed unless you are replacing it.BACK.CHAPTER. Apply sealant to the bolt threads before installing the bolt to prevent oil leakage from the bolt. D Use the SSTs to remove the pilot bearing.16 in} PILOT BEARING 49 E011 1A0 Ä ÀÆ Â Ã Å Ç Á CRANK SHAFT EXCEPT G6 1 6 3 49 E011 1A0 5 2 4 CONTINUED H–9 . 49 E011 1A0 Flywheel Installation Note 1.INDEX CLUTCH UNIT Clutch Cover Removal Note 1. Gradually tighten the flywheel lock bolts in a crisscross pattern. 2. 4. Hold the flywheel using the SST. Hand-tighten the flywheel lock bolts.INDEX RANG. 2. Install the SST to the flywheel.REPAIR MANUAL PAGES. 5. FROM. Loosen each bolt one turn at a time in a crisscross pattern until spring tension is released.0 mm {0. Install the flywheel to the crankshaft. 3 1 6 EXCEPT G6 49 E011 1A0 5 4 2 49 1285 071 Flywheel Removal Note 1.TO. F2 CIS. F2 Carb D Install a new pilot bearing using a pipe until depth is as follows: Depth 4. MANUAL TO. MODEL . G6 Pilot Bearing Installation Note G6. Install the SSTs. Remove the bolts evenly and gradually in a crisscross pattern.

020 in} max. Tighten the bolts evenly and gradually in a crisscross pattern.6 mm {0. Measure the flatness of the pressure plate using a straight edge and a feeler gauge.024 in} min. 3. mount a dial indicator on the cylinder block. 49 E011 1A0 49 SE01 310A 5.2 mm {0—0.6 mm {0. When checking the diaphragm spring fingers.CHAPTER.DRFT. Clearance 0. CONTINUED H–10 .TO. 2. DEPTH Clutch Disc Installation Note D Hold the clutch disc in position using the SST.030 in} max.5 mm {0. Misalignment 0. MANUAL TO. WL Turbo D Install a new pilot bearing using a pipe until protrusion height is as follows: Protrusion height 0—0.008 in} PILOT BEARING FLY WHEEL CLUTCH COVER INSPECTION 1. 2. 49 SE01 310A Clutch Cover Installation Note 1.BACK. FROM.INDEX RANG. Replace the clutch cover if not as specified. Rotate the flywheel and check for misaligned diaphragm spring fingers. Depth 0. 4.INDEX CLUTCH UNIT WL.REPAIR MANUAL PAGES. Measure the wear of the diaphragm spring figures. Install the SSTs. MODEL .

If runout is excessive. 3. Thickness 0. Measure the flywheel runout using a dial indicator.3 mm {0. Runout 0. 2. clutch release collar may not operate properly. If the collar sticks or has excessive resistance.CHAPTER. MANUAL TO.2 mm {0. replace the clutch disc. 2.INDEX CLUTCH UNIT CLUTCH DISC INSPECTION 1. FLYWHEEL INSPECTION 1. replace the clutch release collar. 3. Otherwise.DRFT. Measure the clutch disc runout using a dial indicator. Turn the collar while applying force in the axial direction.012 in} min.INDEX RANG.TO.012 in} FLYWHEEL PILOT BEARING INSPECTION 1. If runout is excessive. 4. Install a dial indicator on the cylinder block.3 mm {0. If clutch disc thickness is less than the minimum. CLUTCH RELEASE COLLAR INSPECTION Caution D Cleaning the clutch release collar with cleaning fluids or a steam cleaner can wash the grease out of the sealed bearing. turn the bearing while applying force in the axial direction. 2. 1. FROM. CONTINUED H–11 . replace the flywheel. Using vernier calipers. replace the clutch disc.079 in} max. Runout 0. 0.REPAIR MANUAL PAGES.7 mm {0. replace it.BACK.027 in} max. Without removing the pilot bearing from the flywheel. MODEL . If the bearing sticks or has excessive resistance. measure the thickness of the lining at a rivet head on both sides. 2.

.m... FROM.....5—4.. TRANSMISSION OIL REPLACEMENT 1.INDEX RANG...... Tightening torque A: 25—39 N..J1-3/7 2..MAIN...INDEX MANUAL TRANSMISSION (M15M-D....... 29—43 ft...6 US qt. J1-1 TRANSMISSION OIL INSPECTION .. 3.. Install the drain plug B with new washer. add the specified oil from the check plug hole.....lbf} Add the specified oil from check plug A port until the level reaches the brim of check plug hole......8 Imp qt} (M15M-D) 2......lbf} 2... Install a new check plug A.......8 Imp qt} (M15M-D) 2.... VEHICLE SPEEDOMETER SENSOR INSPECTION ... J1-1 TRANSMISSION OIL REPLACEMENT ..0—6..m {2....J1-2 MANUAL TRANSMISSION REMOVAL/INSTALLATION ...TO. Drain the oil into a container.m. J1-2 VEHICLE SPEEDOMETER SENSOR REMOVAL/INSTALLATION ......2 Imp qt} (M15MX-D) 6....0 L {2...m...... Tightening torque B: 40—58 N.......... Tightening torque A: 25—39 N.. Verify that the oil is at the brim of the check plug hole as shown......... J1-2 MANUAL TRANSMISSION TRANSMISSION OIL INSPECTION 1..2 Imp qt} (M15MX-D) 3.m {2.6 US qt. MANUAL TO. Clean the drain plug B... Install a new check plug A...5 L {2. 5.... Remove the check plug A.0 kgf.....0 L {2.....0 kgf.... 2....5-4....1 US qt.......... If it is low........ Specified oil Grade: API service GL-4 or GL-5 Viscosity: SAE 75W-90 (All season) or SAE 80W-90 (Above 10 °C {50 °F}) Capacity: 2..lbf} CONTINUED J1-1 ..REPAIR MANUAL PAGES. MODEL .... 1...5 L {2.......0 kgf..... J1-1/2 OIL SEAL (M15M-D) REPLACEMENT ...BACK...... 19—28 ft.m {4.DRFT. Specified oil Grade: API service GL-4 or GL-5 Viscosity: SAE 75W-90 (All season) or SAE 80W-90 (Above 10 °C {50 °F}) Capacity: 2.. 4.... 2... Remove the drain plug B with washer and the check plug A. 1...1 US qt...... 19—28 ft. M15MX-D) MANUAL TRANSMISSION .

Remove the vehicle speedometer sensor. 2. Add the transmission oil.REPAIR MANUAL PAGES. Disconnect the vehicle speedometer sensor connector. 5. 4.TO. PROPELLER SHAFT REMOVAL/ INSTALLATION.9—10.) 2. (Refer to section L.DRFT. Measure voltage between terminals of the vehicle speedometer sensor while the gear is turning.BACK.INDEX MANUAL TRANSMISSION 6. 5. Connect the vehicle speedometer sensor connector. Apply the specified oil to new oil seal. (Refer to MANUAL TRANSMISSION. PROPELLER SHAFT (4x2).cm.m {80—110 kgf.4 in.) Install the propeller shaft.) Connect the negative battery cable.) 7. FROM. Inspect wiring harness. Remove the propeller shaft. Install the oil seal until it touches the case using a suitable piece of pipe. 2. 3. (Instrument cluster-Vehicle speedometer sensor) Replace vehicle speedometer sensor. Meter needle Action Speedometer sensor is normal. (Refer to MANUAL TRANSMISSION. TRANSMISSION OIL REPLACEMENT. PROPELLER SHAFT (4x2). (Refer to section L. PROPELLER SHAFT REMOVAL/ INSTALLATION. VEHICLE SPEEDOMETER SENSOR INSPECTION 1. Remove the vehicle speedometer sensor.INDEX RANG. Install the vehicle speedometer sensor. Drain the transmission oil. 69.CHAPTER. Moves slightly under 5 V Does not move 4. VEHICLE SPEEDOMETER SENSOR REMOVAL/ INSTALLATION. VEHICLE SPEEDOMETER SENSOR REMOVAL/ INSTALLATION. 9. Install the vehicle speedometer sensor.7 N. Disconnect the negative battery cable. J1-2 CONTINUED .) VEHICLE SPEEDOMETER SENSOR REMOVAL/INSTALLATION 1. Tightening torque 7. MANUAL TO. 6.5—95.Ibf} 7. MODEL . 8. OIL SEAL (M15M-D) REPLACEMENT 1. (Refer to MANUAL TRANSMISSION. Drain the transmission oil. TRANSMISSION OIL REPLACEMENT. Add the specified type and amount of transmission oil. (Refer to MANUAL TRANSMISSION. Apply transmission oil to new O-ring and install it on new vehicle speedometer sensor. 3.) 3. Remove the oil seal using a screwdriver.

1 2 3 4 5 6 7 8 9 10 11 Shift lever knob Console Dust boot Change boot upper plate Boot Dust boot Gasket Wave washer Change bush Change lever Change seat 12 13 14 15 16 17 18 19 Speedometer sensor connector Back-up light switch connector Neutral switch connector (F2 CIS) Front pipe bracket Clutch release cylinder Crossmember ☞ Removal Note Transmission lower mount Transmission ☞ Removal Note ☞ Installation Note CONTINUED J1-3 . Warm up the engine and transmission. TRANSMISSION OIL REPLACEMENT.CHAPTER. Install in the reverse order of removal.INDEX MANUAL TRANSMISSION MANUAL TRANSMISSION REMOVAL/INSTALLATION 4x2(M15M-D) 1. Remove in the order indicated in the table. Drain the transmission oil into a container. Remove the starter. and verify the transmission operation.INDEX RANG. Remove the propeller shaft.TO. 7. MODEL .) 8.REPAIR MANUAL PAGES. 2. 3. inspect for oil leakage.BACK. (Refer to MANUAL TRANSMISSION. MANUAL TO. Disconnect the negative battery cable. FROM. PROPELLER SHAFT REMOVAL/INSTALLATION. STARTER REMOVAL/INSTALLATION.) 5. PROPELLER SHAFT (4x2).DRFT. 6. (Refer to section G. STARTING SYSTEM. Add the specified type and amount of transmission oil. (Refer to section L.) 4.

REPAIR MANUAL PAGES.CHAPTER.BACK.INDEX MANUAL TRANSMISSION 1 2 3 4 5 6 7 8 9 10 11 Shift lever knob Console Dust boot Change boot upper plate Boot Dust boot Gasket Wave washer Change bush Change lever Change seat 12 13 14 15 16 17 18 19 Speedometer sensor connector Back-up light switch connector Front pipe bracket Clutch release cylinder Crossmember ☞ Removal Note Dynamic damper Transmission lower mount Transmission ☞ Removal Note & Installation Note CONTINUED J1-4 . FROM. MANUAL TO.TO.INDEX RANG. MODEL .DRFT.

Maintain the stability of the transmission while installing it.TO.INDEX MANUAL TRANSMISSION Crossmember removal note • Securely support the transmission on a transmission jack. FROM.BACK. 2. It can slip or fall. Transmission installation note Warning • A transmission that is not securely supported on a transmission jack is dangerous.INDEX RANG. MANUAL TO.DRFT.CHAPTER.REPAIR MANUAL PAGES. Transmission removal note • Maintain the stability of the transmission while removing it. Place the transmission on a transmission jack. Never work without the transmission jack until crossmember installation is finished. MODEL . 1. CONTINUED J1-5 . causing serious injury. then remove the crossmember.

) 5. Crossmember removal Note CONTINUED J1-6 .) 8. Disconnect the negative battery cable.) (Refer to section J3. Drain the transmission and transfer oil into a container. FROM. (Refer to section G.BACK.CHAPTER. 6. TRANSFER. Install in the reverse order of removal. (Refer to section L. 3. Add the specified type and amount of transmission and transfer oil. Remove in the order indicated in the table. and verify the transmission operation.DRFT. MODEL . FRONT PROPELLER SHAFT REMOVAL/INSTALLATION. (Refer to MANUAL TRANSMISSION. REAR PROPELLER SHAFT (4x4). 2. REAR PROPELLER SHAFT REMOVAL/INSTALLATION.REPAIR MANUAL PAGES. TRANSFER OIL REPLACEMENT.INDEX RANG. STARTER REMOVAL/INSTALLATION. inspect for oil leakage.INDEX MANUAL TRANSMISSION 4x4(M15MX-D) 1.TO.) (Refer to section L. Remove the front and rear propeller shaft. MANUAL TRANSMISSION REMOVAL/INSTALLATION. Warm up the engine and transmission.) 4. 1 2 3 4 5 6 7 8 9 10 11 Shift lever knob Console Dust boot Change boot upper mount Boot Dust boot Gasket Wave washer Change bush Change lever Change seat 12 13 14 15 16 17 18 Transfer under cover Speedometer sensor connector Back-up light switch connector 4x4 indicator switch connector Front pipe bracket Clutch release cylinder Crossmember ☞ MANUAL TRANSMISSION. STARTING SYSTEM. 4x2 (M15M-D). Remove the starter. 7. TRANSMISSION OIL REPLACEMENT. MANUAL TO. FRONT PROPELLER SHAFT (4x4).

MODEL .BACK.DRFT. They can slip or fall. FROM. CONTINUED J1-7 . Maintain the stability of the transmission and transfer while installing them. Place the transmission and transfer on a transmission jack.REPAIR MANUAL PAGES. Transmission and transfer installation note Warning • A transmission and transfer that are not securely supported on a transmission jack are dangerous.INDEX RANG.CHAPTER. Never work without the transmission jack until crossmember installation is finished.INDEX MANUAL TRANSMISSION 19 20 Transmission lower mount Transmission and transfer ☞ Removal Note & Installation Note Transmission and transfer removal note • Maintain the stability of the transmission and transfer while removing them . 1.TO. MANUAL TO. 2. causing serious injury.

.0 kgf·m. . . TRANSMISSION OIL INSPECTION . Specified oil Grade: API service GL–4 or GL–5 Viscosity: SAE 75W–90 (All season) or SAE 80W–90 (Above 10°C {50°F}) DRAIN PLUG A DRAIN PLUG B FILLER PLUG HOLE 4. . . . .8 L {3. . . . .J2–2 MANUAL TRANSMISSION REMOVAL/INSTALLATION . add the specified oil from the filler plug hole.REPAIR MANUAL PAGES. Tightening torque A: 40—58 N·m {4. . 3. . OIL SEAL (R15M–D) REPLACEMENT .INDEX MANUAL TRANSMISSION (R15M–D. . FILLER PLUG 2. . Remove the filler plug and add the specified oil through the filler plug port until the level rises to the bottom of the port.2 kgf·m. .6—4.2 L {3. . . . . . . .0 US qt.1—3.4 US qt. . . . Install a new filler plug. Remove the filler plug.8 lmp qt} (R15MX–D) 3.INDEX RANG. . R15MX–D) MANUAL TRANSMISSION . . 19—28 ft·lbf} FILLER PLUG HOLE CONTINUED J2–1 .MAIN. .. . . 2. 2. . FROM. 2. . .0—6. . Remove drain plugs A and B. . . . . . MANUAL TO. Clean the drain plug A..DRFT. . . If it is low. J2–3/9 MANUAL TRANSMISSION TRANSMISSION OIL INSPECTION 1. 29—43 ft·lbf} B: 21—31 N·m {2. . MODEL .0 kgf·m. . . VEHICLE SPEEDOMETER SENSOR REMOVAL/INSTALLATION . . . . . TRANSMISSION OIL REPLACEMENT . . . . . Specified oil Grade: API service GL–4 or GL–5 Viscosity: SAE 75W–90 (All season) or SAE 80W–90 (Above 10°C {50°F}) Capacity: 2.BACK. . . . 16—23 ft·lbf} FILLER PLUG VEHICLE SPEEDOMETER SENSOR INSPECTION. . Install the drain plug A with new washer and a new drain plug B. J2–1 J2–1 J2–1/2 J2–2 J2–2 TRANSMISSION OIL REPLACEMENT 1. and drain the oil into a container.5 lmp qt} (R15M–D) 3. . . . Verify that the oil is at the brim of the filler plug hole as shown. Tightening torque 25—39 N·m {2.TO. . . .

PROPELLER SHAFT REMOVAL/INSTALLATION.BACK.) VEHICLE SPEEDOMETER SENSOR REMOVAL/INSTALLATION (Refer to section J1. MANUAL TRANSMISSION. Apply the specified oil to the new oil seal. 2. PROPELLER SHAFT (4x2). Tightening torque 25—39 N·m {2. (Refer to section L. Install the propeller shaft.REPAIR MANUAL PAGES.) CONTINUED J2–2 .TO. (Refer to section L. 4.DRFT.) 7. VEHICLE SPEEDOMETER SENSOR INSPECTION. 19—28 ft·lbf} OIL SEAL (R15M–D) REPLACEMENT 1. VEHICLE SPEEDOMETER SENSOR REMOVAL/INSTALLATION.INDEX RANG. PIPE 6. MANUAL TO. Install the oil seal until it touches the case using a suitable piece of pipe. MODEL .) 3. MANUAL TRANSMISSION. TRANSMISSION OIL REPLACEMENT. Install a new filler plug. PROPELLER SHAFT (4x2). Add the transmission oil. PROPELLER SHAFT REMOVAL/INSTALLATION.) VEHICLE SPEEDOMETER SENSOR INSPECTION (Refer to section J1. (Refer to MANUAL TRANSMISSION.CHAPTER. Remove the oil seal using a screwdriver. Drain the transmission oil. Remove the propeller shaft. 5.6—4.0 kgf·m.INDEX MANUAL TRANSMISSION 1. FROM.

5—95.7. Install in the reverse order of removal. 3. 2. 6.) 4.9—2.9—10.6—2. Warm up the engine and transmission. Add the specified amount and type of transmission oil. 28—33} N·m {kgf·m.2—4. 51—65} 19—25 {1. STARTER REMOVAL/INSTALLATION.0—9. inspect for oil leakage.3.3. F2 7.INDEX MANUAL TRANSMISSION MANUAL TRANSMISSION REMOVAL/INSTALLATION 4 2 (R15M–D) 1.9—10. MANUAL TO.5—95. Disconnect the negative battery cable.3.7 N·m {80—110 kgf·cm. ft·lbf} 1 2 3 4 5 6 7 8 9 10 11 Shift lever knob Console Dust boot Change boot upper plate Boot Dust boot Gasket Wave washer Change bush Change lever Change seat 12 13 14 15 16 17 18 19 Vehicle speedometer sensor connector Back–up light switch connector Neutral switch connector (F2 CIS) Front pipe bracket Clutch release cylinder Crossmember + Removal Note Transmission lower mount Transmission + Removal note + Installation note CONTINUED J2–3 .0. 28—38} 7.4 in·lbf} 32—46 {3.9.CHAPTER.2—2.0. Remove the propeller shaft. TRANSMISSION OIL REPLACEMENT.8—5.3. 69. 14—18} 69—88 {7.0—9. (Refer to section G. Remove in the order indicated in the table.) 5.BACK. PROPELLER SHAFT (4x2).7.INDEX RANG. (Refer to section L.0. Drain the transmission oil into a container. 51—65} A A 16—22 {1.8—5. 28—38} 16—22 {1.DRFT.8—5.8—4. 69. Remove the starter. STARTING SYSTEM.REPAIR MANUAL PAGES.) 8. 24—33} 22—28 {2.3. 28—38} 38—51 {3. 7.TO.6. and verify the transmission operation.0. MODEL .0—9. 51—65} 69—88 {7.7 N·m {80—110 kgf·cm. (Refer to MANUAL TRANSMISSION. 16—20} 38—46 {3. 51—65} 38—51 {3.0—9. 12—16} 69—88 {7.6—2.4 in·lbf} R 69—88 {7. FROM. PROPELLER SHAFT REMOVAL/INSTALLATION. 12—16} ST 38—51 {3.

MODEL .DRFT.INDEX MANUAL TRANSMISSION G6 1 2 3 4 5 6 7 8 9 10 11 Shift lever knob Console Dust boot Change boot upper plate Boot Dust boot Gasket Wave washer Change bush Change lever Change seat 12 13 14 15 16 17 18 19 Vehicle speedometer sensor connector Back-up light switch connector Neutral switch connector Front pipe bracket Clutch release cylinder Crossmember ☞ Removal Note Transmission lower mount Transmission ☞ Removal note ☞ Installation note CONTINUED J2-4 . FROM.CHAPTER.TO.INDEX RANG.REPAIR MANUAL PAGES. MANUAL TO.BACK.

12—16} 32—46 {3. ft·lbf} 1 2 3 4 5 6 7 8 9 10 Shift lever knob Console Dust boot Change boot upper plate Boot Dust boot Gasket Wave washer Change bush Change lever 11 12 13 14 15 16 17 18 Change seat Vehicle speedometer sensor connector Back-up light switch connector Front pipe bracket Clutch release cylinder Crossmember + Removal Note Transmission lower mount Transmission + Removal note + Installation note CONTINUED J2–5 .8—5.9—2. 69.TO.CHAPTER. 14—18} 38—51 {3.3.REPAIR MANUAL PAGES.3.BACK.INDEX RANG. FROM.3.7.8—5. 28—38} A 16—22 {1.3.9. 24—33} 22—28 {2.7 N·m {80—110 kgf·cm. 16—20} 38—46 {3. 28—33} N·m {kgf·m.6—2.2—2.DRFT.INDEX MANUAL TRANSMISSION WL. 12—16} A 16—22 {1.4 in·lbf} R 19—25 {1.6—2.2—4. WL TURBO 7. MANUAL TO.6.5—95.8—4.9—10. 28—38} 38—51 {3. MODEL .7.

INDEX RANG.REPAIR MANUAL PAGES. It can slip or fall. D Maintain the stability of the transmission while removing it. FROM. Never work without the transmission jack until crossmember installation is finished. ST CONTINUED J2–6 . 2. MANUAL TO.INDEX MANUAL TRANSMISSION Crossmember removal note D Securely support the transmission on a transmission jack. then remove the crossmember. Maintain the stability of the transmission while installing them. Place the transmission on a transmission jack. 1. Transmission removal note Warning D Do not allow the transmission to fall from the transmission jack. causing serious injury. Transmission installation note Warning D A transmission that is not securely supported on a transmission jack is dangerous.DRFT.TO. MODEL .BACK.CHAPTER.

3.3. STARTING SYSTEM. 27—36} 38—51 {3. FROM. TRANSFER. MODEL . Add the specified type and amount of transmission and transfer oil. TRANSMISSION OIL REPLACEMENT. Remove the starter.0.5—95. TRANSFER OIL REPLACEMENT. REAR PROPELLER SHAFT (4x4).8—5.3. Remove in the order indicated in the table.) 5. Install in the reverse order of removal. 14—18} A 38—51 {3.4—5.7—5.7.3.8—5. 24—33} 69—88 {7. Warm up the engine and transmission.REPAIR MANUAL PAGES. 28—38} 16—22 {1.8—5.0—9. Remove the front pipe.4 in·lbf} R R 38—51 {3. Drain the transmission and transfer oil into a container.1.2—4.) 6. 28—38} 19—25 {1. 69.) 4. 32—39} N·m {kgf·m.TO. FRONT PROPELLER SHAFT REMOVAL/INSTALLATION.7 N·m {80—110 kgf·cm. REAR PROPELLER SHAFT REMOVAL/INSTALLATION. 51—65} A 7. and verify the transmission operation. EXHAUST SYSTEM.6.9—2.) (Refer to section L.9—10.INDEX MANUAL TRANSMISSION 4 4 (R15MX–D) 1. inspect for oil leakage. (Refer to section G.4 in·lbf} 37—50 {3.INDEX RANG. 69. 8.7 N·m {80—110 kgf·cm. 7.DRFT. MANUAL TO.5—95. G6 7.8—5. ft·lbf} CONTINUED J2–7 . 2.9—10. 3. (G6 engine) (Refer to section F2.) (Refer to section J3. 12—16} 32—46 {3. (Refer to MANUAL TRANSMISSION. Remove the front and rear propeller shaft. EXHAUST SYSTEM REMOVAL/INSTALLATION.) 9.3.CHAPTER. Disconnect the negative battery cable.BACK. FRONT PROPELLER SHAFT (4x4).3. (Refer to section L. 28—38} 44—53 {4. 28—38} 38—51 {3.6—2. STARTER REMOVAL/INSTALLATION.

3. MANUAL TO. ft·lbf} CONTINUED J2–8 .7.7 N·m {80—110 kgf·cm. 4 2 (R15M–D).INDEX MANUAL TRANSMISSION 1 2 3 4 5 6 7 8 9 10 11 12 13 Shift lever knob Console Dust boot Change boot upper mount Boot Dust boot Gasket Wave washer Change bush Change lever Change seat Transfer under cover Vehicle speedometer sensor connector 21 22 14 15 16 17 18 19 20 Back–up light switch connector Neutral switch connector 4x4 indicator switch connector Transfer neutral switch connector (RFW model) Front pipe bracket Clutch release cylinder Crossmember + MANUAL TRANSMISSION. MANUAL TRANSMISSION REMOVAL/INSTALLATION. FROM.BACK. 28—38} 32—46 {3. Crossmember removal note Transmission lower mount Transmission and transfer + Removal note + Installation note WL. 32—39} 22—28 {2.REPAIR MANUAL PAGES.1.2—2.3.3. MODEL .3.9. 28—38} ST A 38—51 {3. 16—20} N·m {kgf·m. 14—18} 38—51 {3.INDEX RANG.9—10.6—2.7—5.5—95.4—5. 12—16} A 37—50 {3. 27—36} 44—53 {4. WL TURBO 7. 69.8—5.TO.2—4.DRFT.9—2.8—5. 24—33} 16—22 {1.6.4 in·lbf} R R 19—25 {1.CHAPTER.

1.DRFT. Transmission and transfer installation note Warning D A transmission and transfer that are not securely supported on a transmission jack are dangerous. 4 2 (R15M–D). They can slip or fall.INDEX MANUAL TRANSMISSION 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 Shift lever knob Console Dust boot Change boot upper mount Boot Dust boot Gasket Wave washer Change bush Change lever Change seat Transfer under cover Vehicle speedometer sensor connector Back–up light switch connector Transfer neutral switch connector (RFW model) 4x4 indicator switch connector Front pipe bracket Clutch release cylinder Crossmember + MANUAL TRANSMISSION. MANUAL TRANSMISSION REMOVAL/INSTALLATION. 20 21 CONTINUED J2–9 .INDEX RANG. Place the transmission and transfer on a transmission jack. causing serious injury. Never work without the transmission jack until crossmember installation is finished.REPAIR MANUAL PAGES. FROM. MODEL .BACK.CHAPTER.TO. 2. MANUAL TO. Maintain the stability of the transmission and transfer while installing them. D Maintain the stability of the transmission and transfer while removing them. Crossmember removal note Transmission lower mount Transmission and transfer + Removal note + Installation note Transmission and transfer removal note Warning D Do not allow the transmission to fall from the transmission jack.

MAIN.......0—6..0 kgf.. If it is low.8 lmp qt} 2........... Install the filler plug with new washer. Specified oil Grade: API service GL-4 or GL-5 Viscosity: SAE 75W-90 (All season) or SAE 80W-90 (Above 10 °C {50 °F}) Capacity: 2..m {4. Tightening torque 40—58 N-m {4. 4...lbf} CONTINUED J3-1 .. Tightening torque 40—58 N. FROM..1 USqt..m..1..0 L {2......0—6.TO.DRFT. Drain the oil into a container......... J3-1 TRANSFER OIL REPLACEMENT 1.INDEX RANG..0 kgf. Clean the filler and drain plugs.... 4... 2... MODEL ..lbf} 5.J3-1 TRANSFER OIL INSPECTION ....0 L {2.. 29—43 ft...J3-1 TRANSFER TRANSFER OIL INSPECTION 1..0 kgf.1 USqt...... 3.. Remove the filler plug with washer....m......lbf} 6... Add the specified oil from filler plug port until the level reaches the brim of filler plug hole. TRANSFER OIL REPLACEMENT ........... Install the drain plug with new washer. MANUAL TO..0-6.. Tightening torque 40—58 N-m {4. Clean the filler plug.. 29—43 ft... Specified oil Grade: API service GL-4 or GL-5 Viscosity: SAE 75W-90 (All season) or SAE 80W-90 (Above 10 °C {50 °F}) Capacity: 2..... add the specified oil from the filler plug hole.INDEX TRANSFER TRANSFER .REPAIR MANUAL PAGES.....BACK... Install the filler plug with new washer... Verify that the oil is at the brim of the filler plug hole as shown....8lmpqt} 3...... 29—43 ft... Remove the filler plug with washer and drain plug with washer.1..m..

. . .7—5. . Remove the propeller shaft from the extension housing and immediately install the SST to prevent oil leakage. .. . . . . . Install in the reverse order of removal. . . . . . . TAG MARK Nut Installation Note ST D Tighten the center bearing installation nuts with the vehicle *unloaded. . . . . . . . . . Remove in the order indicated in the table. and install the propeller shaft. . . . . . . 37—43} WL TURBO. . . . spare tire. . Before removing the propeller shaft.INDEX RANG. . . . . PROPELLER SHAFT INSPECTION . . . . . . . REAR PROPELLER SHAFT INSPECTION . . .MAIN. . *unloaded. . . . . . . MODEL . . L–3 L–3/4 L–5 L–5 L–5 PROPELLER SHAFT (4 2) PROPELLER SHAFT REMOVAL/INSTALLATION 1. ft·lbf} Propeller Shaft Installation Note D Align the marks made during removal. .TO. . REAR PROPELLER SHAFT (4 4) . align the differential companion flange precast marking with the tag on the propeller shaft. .Fuel tank is full. . . . 50—58 {5. . . . . jack and tools are in designated position. TAG MARK 1 2 3 Bolt. nut Nut + Installation Note Propeller shaft + Removal Note + Installation Note Propeller Shaft Removal Note 1. . . . . . . F2 CIS. . . . . . . .0. . . . FRONT PROPELLER SHAFT REMOVAL/ INSTALLATION . . 2. . . . L–1 L–1 L–2 L–2 L–2 FRONT PROPELLER SHAFT INSPECTION . . . . . . . F2 CARB: SST 49 S120 440 49 0259 440 37—52 {3. . . . . . . G6: WL. . . . . . . . . MANUAL TO. FRONT PROPELLER SHAFT (4 4) . . . 27—39} N·m {kgf·m. . . . 2.INDEX PROPELLER SHAFT PROPELLER SHAFT (4 2) . . FROM. .REPAIR MANUAL PAGES. . . . ..BACK. . . . . . . . . .0—6. FRONT PROPELLER SHAFT DISASSEMBLY/ASSEMBLY . . . . PROPELLER SHAFT REMOVAL/ INSTALLATION . engine coolant and engine oil are at specified levels. . CONTINUED L–1 . . . . REAR PROPELLER SHAFT REMOVAL/ INSTALLATION . . . . . put marks on the yoke and the companion flange on the propeller shaft tag side for proper reinstallation.4. If installing a new propeller shaft.DRFT. . . . . . . .

INDEX PROPELLER SHAFT (4 2).0—12. replace the propeller shaft. 4. MODEL .INDEX RANG. FROM. If the runout is excessive. 21—22} 2.BACK.3—1. Runout 0.4 mm {0.DRFT. If installing a new propeller shaft.REPAIR MANUAL PAGES. 2.8—3. TAG MARK Front Propeller Shaft Installation Note D Align the marks made during removal.7—10. MANUAL TO. and inspect joint play. replace the propeller shaft. Move the universal joint in the direction shown. 28—30 {2. Remove in the order indicated in the table. Measure the propeller shaft runout using a dial indicator. 2. 3.1. align the precast marking with the tag on the front propeller shaft.016 in} max.0 kgf·cm.4 in·lbf} N·m {kgf·m. put marks on the yoke and the companion flange on the propeller shaft tag side for proper reinstallation.1 N·m {3.TO. nut Front propeller shaft + Removal Note + Installation Note Front Propeller Shaft Removal Note D Before removing the front propeller shaft.CHAPTER. Install in the reverse order of removal. Note D Starting torque 0. FRONT PROPELLER SHAFT (4 PROPELLER SHAFT INSPECTION 1. 4) FRONT PROPELLER SHAFT (4 4) FRONT PROPELLER SHAFT REMOVAL/ INSTALLATION 1. CONTINUED L–2 . If there is excessive play or the starting torque is not within the specification. ft·lbf} 1 2 Bolt. and install the front propeller shaft.

9 in·lbf} MARK ST 2. Measure the front propeller shaft runout using a dial indicator.REPAIR MANUAL PAGES.7—6. If there is excessive play or the starting torque is not within the specification. 2. Universal joint Disassembly Note 1.3—0.TO. Push one bearing cup out of the propeller shaft by tapping the yoke with a plastic hammer.DRFT. Disassemble in the order indicated in the table. 1 2 3 R Snap ring + Disassembly Note Universal joint yoke Universal joint + Disassembly Note + Assembly Note Sliding yoke Propeller shaft 4 5 Snap ring Disassembly Note 1. Note D Starting torque 0.INDEX FRONT PROPELLER SHAFT (4 4) FRONT PROPELLER SHAFT DISASSEMBLY/ASSEMBLY 1.) YOKE BEARING CUP CONTINUED L–3 . MODEL . Runout 0. FROM. Remove the snap ring.0—8.7 N·m {3. R TAG MARK R R FRONT PROPELLER SHAFT INSPECTION 1.INDEX RANG. 2. Mark the yoke and propeller shaft for proper reassembly. Assemble in the reverse order of disassembly. 3. Clamp the propeller shaft in a vise. replace the front propeller shaft. 3.BACK. (Refer to FRONT PROPELLER SHAFT (4 4).4 mm {0. 2. FRONT PROPELLER SHAFT DISASSEMBLY/ASSEMBLY. and inspect the joint play.0 kgf·cm. Move the universal joint in the direction shown.CHAPTER. 4. repair the front propeller shaft. If the runout is excessive. MANUAL TO.016 in} max.

6.0528} 1. MANUAL TO.22 {0. Measure the snap ring clearance. Remove the opposite bearing cup in the same manner.04—0. MODEL . If there is excessive play or the starting torque is not within the specification.BACK. and inspect joint play.7 N·m {3.24 {0.7—6.0543} SNAP RING CLEARANCE SPIDER 4. SPIDER 3.34 {0. 2.36 {0.0520} 1. Snap ring thicknesses mm {in} 1.DRFT.26 {0. Set the new spider into the yoke and tap in a new bearing cup until the snap ring groove is exposed. Universal joint Assembly Note 1.0 kgf·cm. 2. 3.REPAIR MANUAL PAGES.9 in ·lbf} CONTINUED L–4 .38 {0. then select and install two new snap rings of equal thickness.INDEX FRONT PROPELLER SHAFT (4 4) 1. Move the universal joint in the direction shown.32 {0.45g {0. Separate the propeller shaft and yoke.INDEX RANG. 5. 4. Remove the bearing cups and the spider from the yoke in the same manner as in Steps 1 and 2.3—0.0488} 1.CHAPTER. Verify that the inside of the bearing cup is filled with 1. 2.0536} 1.TO.30 {0. Add the specified amount of disulphide molybdem grease as necessary.0512} BEARING CUP YOKE 1.0496} 1.0504} 1.15—1. Note D Starting torque 0. Install the remaining bearing cups and snap rings as in Steps 1—3.05 oz} grease. replace the front propeller shaft.0480} 1. Clamp the yoke in a vise. FROM.28 {0.0—8.

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RANG.DRFT.REPAIR MANUAL PAGES. FROM. MANUAL

TO. MODEL .INDEX

REAR PROPELLER SHAFT (4 4)

REAR PROPELLER SHAFT (4 4)
REAR PROPELLER SHAFT REMOVAL/INSTALLATION 1. Remove in the order indicated in the table. 2. Install in the reverse order of removal.

TAG

MARK

50—58 {5.0—6.0, 37—43}

REAR PROPELLER SHAFT INSPECTION 1. Measure the rear propeller shaft runout using a dial indicator. Runout 0.4 mm {0.016 in} max.

37—52 {3.7—5.4, 27—39} 50—58 {5.0—6.0, 37—43} N·m {kgf·m, ft·lbf}

1 2

Bolt, nut Nut + PROPELLER SHAFT (4 2), PROPELLER SHAFT REMOVAL/INSTALLATION, Nut Installation Note Rear propeller shaft + Removal Note + Installation Note Dynamic damper (WL Turbo)

2. If the runout is excessive, replace the rear propeller shaft. 3. Move the universal joint in the direction shown. Inspect starting torque and joint play. Note D Starting torque 0.3—1.1 N·m {3.0—12.0 kgf·cm, 2.7—10.4 in·lbf}

3

4

Rear Propeller Shaft Removal Note 1. Before removing the rear propeller shaft, put marks on the yoke and the companion flange on the rear propeller shaft tag side for proper reinstallation.
TAG MARK

ST

4. If there is excessive play or the starting torque is not within the specification, replace the rear propeller shaft.

Rear Propeller Shaft Installation Note D Align the marks made during removal, and install the rear propeller shaft. If installing a new propeller shaft, align precast marking with the tag on the rear propeller shaft.

CONTINUED

L–5

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RANG.DRFT.REPAIR MANUAL PAGES. FROM. MANUAL

TO. MODEL .INDEX

FRONT AND REAR AXLES
GENERAL PROCEDURES . . . . . . . . . . . . . . . . . . FRONT AXLE (4 2) . . . . . . . . . . . . . . . . . . . . . . . WHEEL HUB, STEERING KNUCKLE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . WHEEL HUB, STEERING KNUCKLE REMOVAL/INSTALLATION . . . . . . . . . . . . . . FRONT AXLE (4 4) . . . . . . . . . . . . . . . . . . . . . . . WHEEL HUB, STEERING KNUCKLE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . WHEEL HUB, STEERING KNUCKLE REMOVAL/INSTALLATION . . . . . . . . . . . . . . REAR AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REAR AXLE INSPECTION . . . . . . . . . . . . . . . . AXLE SHAFT REMOVAL/ INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . DRIVE SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DRIVE SHAFT REMOVAL/ INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . DRIVE SHAFT DISASSEMBLY/ ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . OUTPUT SHAFT (MFW) REMOVAL/INSTALLATION . . . . . . . . . . . . . . OUTPUT SHAFT DISASSEMBLY/ASSEMBLY . . . . . . . . . . . . . REAR DIFFERENTIAL . . . . . . . . . . . . . . . . . . . . . REAR DIFFERENTIAL OIL INSPECTION . . . . REAR DIFFERENTIAL OIL REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . REAR DIFFERENTIAL REMOVAL/ INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . STANDARD DIFFERENTIAL DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . STANDARD DIFFERENTIAL ASSEMBLY . . . M– 2 M– 2 M– 2 M– 3/5 M– 5 M– 5 M– 6/8 M– 9 M– 9 M– 9/11 M–12 M–12 M–13/15 M–16 M–17/18 M–19 M–19 M–19 M–20 M–21/23 M–24/27 REMOTE FREEWHEEL (RFW) MECHANISM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 4 INDICATOR SWITCH INSPECTION . . . TRANSFER NEUTRAL SWITCH INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . RFW SWITCH INSPECTION . . . . . . . . . . . . . . RFW MAIN SWITCH REMOVAL/ INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . RFW MAIN SWITCH INSPECTION . . . . . . . . ONE-WAY CHECK VALVE INSPECTION . . . LOCK AND FREE SOLENOID VALVES INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . RFW ACTUATOR INSPECTION . . . . . . . . . . . RFW CONTROL MODULE INSPECTION . . . . RFW CONTROL MODULE REMOVAL/ INSPECTION . . . . . . . . . . . . . . JOINT SHAFT COMPONENT REMOVAL/INSTALLATION . . . . . . . . . . . . . . JOINT SHAFT COMPONENT DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . JOINT SHAFT INSPECTION . . . . . . . . . . . . . . JOINT SHAFT COMPONENT ASSEMBLY . . . CONTROL BOX REMOVAL/ INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . CONTROL BOX DISASSEMBLY/ ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . SHIFT FORK INSPECTION . . . . . . . . . . . . . . . FRONT DIFFERENTIAL . . . . . . . . . . . . . . . . . . . . FRONT DIFFERENTIAL OIL INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . FRONT DIFFERENTIAL OIL REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . FRONT DIFFERENTIAL OIL SEAL REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . FRONT DIFFERENTIAL REMOVAL/INSTALLATION . . . . . . . . . . . . . . . FRONT DIFFERENTIAL DISASSEMBLY . . . . FRONT DIFFERENTIAL ASSEMBLY . . . . . . . TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . REMOTE FREEWHEEL (RFW) . . . . . . . . . . . . M–32 M–32 M–32/33 M–33 M–33 M–33 M–34 M–34 M–34 M–35 M–35/36 M–37 M–38/39 M–39 M–40/42 M–42 M–43/44 M–44 M–45 M–45 M–45 M–45 M–46/47 M–48/50 M–51/55 M–56 M–56/62

MANUAL FREEEWHEEL (MFW) MECHANISM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M–32 ON-VEHICLE INSPECTION . . . . . . . . . . . . . . . M–32

CONTINUED

M–1

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GENERAL PROCEDURES, FRONT AXLE (4

2)

GENERAL PROCEDURES
Wheel and tire removal/installation D The removal and installation procedure for the wheels and tires are not mentioned in this section. When a wheel is removed, tighten it to the specified torque. (Refer to section TD, SUSPENSION, Wheels and Tires.) Suspension arm removal/installation D Tighten any part of the suspension that uses rubber bushings only after vehicle has been lowered and unloaded.* *Unloaded: Fuel tank is full. Engine coolant and engine oil are at specified level. Spare tire, jack, and tools are in designated position. Brake line disconnection/connection Caution D Brake fluid will damage painted surfaces. If brake fluid gets on a painted surface, wipe it off immediately.
D Tighten the brake pipe flare nut using the

FRONT AXLE (4 2)
WHEEL HUB, STEERING KNUCKLE INSPECTION Wheel Bearing Play Inspection D After jacking up the vehicle and supporting it at the specified places with safety stands, inspect for noticeable bearing play by holding the top and bottom of the tire. Wheel bearing axial play 0 mm {0 in} Preload Adjustment 1. Verify that the tire rotates smoothly when rotated strongly, and that there is no rough feeling or is abnormal noise from the bearing. 2. Remove the brake caliper component and suspend it by a rope. 3. Remove the hub cap, pull out the cotter pin and remove the set cover. 4. Loosen the locknut to the extent that it can be turned by hand. 5. Attach a pull scale to a hub bolt and measure the frictional force. 6. Tighten the locknut until the reading reaches the specified amount. Preload Frictional force plus 5.9—10.7 N {0.6—1.1 kgf, 1.4—2.4 lbf} 7. Install the set cover, and secure with a new cotter pin. 8. Install the hub cap and brake caliper component.

SST (49 0259 770B). Be sure to modify the brake pipe fIare nut tightening torque to allow use of a torque wrench-SST combination. (Refer to section GI, FUNDAMENTAL PROCEDURES, TORQUE FORMULAS.) D If any brake line has been disconnected any time during the procedure, add brake fluid, bleed the brakes, and inspect leakage after the procedure has been completed. Connectors disconnection/connection D Disconnect the negative battery cable before doing any work that requires the handling of connectors. Reconnect the negative battery cable only after the work is completed.

CONTINUED

M–2

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TO. MODEL .INDEX

FRONT AXLE (4 2)
WHEEL HUB, STEERING KNUCKLE REMOVAL/INSTALLATION 1. Remove in the order indicated in the table. 2. Install in the reverse order of removal.

54—68 {5.5—7.0, 40—50}

108—127 {11—13, 80—94}

SST R R SST R

SST
30—50 {3.0—5.2, 22—50} 80—100 {8.1—10.2, 59—73}

R SST R R

R SST SST

R
45—58 {4.5—6.0, 33—43}

R
19—25 {1.9—2.6, 14—18}

118—156 {12—16, 87—115}

R

R

N·m {kgf·m, ft·lbf}

1 2 3 4 5 6 7 8 9

Hub cap Cotter pin Set cover Locknut Washer Brake caliper component + Removal Note Hub and disc plate component + Installation Note Dust cover Tie-rod end ball joint + section N, MANUAL STEERING, STEERING GEAR AND LINKAGE REMOVAL/ INSTALLATION, Tie-rod End Ball Joint Removal Note Knuckle arm

11

Lower arm ball joint + section R, FRONT SUSPENSION, TORSION BAR SPRING AND LOWER ARM (4 2) REMOVAL/INSTALLATION, Lower Arm Ball Joint/Knuckle Removal Note Upper arm ball joint + section R, FRONT SUSPENSION, UPPER ARM REMOVAL/INSTALLATION, Upper Arm Ball Joint/Knuckle Removal Note Steering knuckle Disc plate + Removal Note Wheel hub + Removal Note Hub bolt + Removal Note + Installation Note

12

13 14 15 16

10

CONTINUED

M–3

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FRONT AXLE (4 2)

17 18 19 20

Outer bearing inner race Oil seal + Installation Note Inner bearing inner race Inner bearing outer race + Removal Note + Installation Note Outer bearing outer race + Removal Note + Installation Note

21

Brake Caliper Component Removal Note D Remove the brake caliper component, and suspend it by a rope.

Outer Bearing Outer Race, Inner Bearing Outer Race Installation Note D Install the bearing outer race using the SSTs and a press. For the other side, reverse the wheel hub and install the outer race.

OUTSIDE BEARING

49 H033 101
INSIDE BEARING

49 B025 001

Disc Plate, Wheel Hub, Hub Bolt Removal Note Note D The hub bolt does not need to be removed unless it is being replaced. 1. After putting markings on the disc plate and the wheel hub, remove the bolt and disassemble the plate and hub. Oil Seal Installation 1. After inserting the bearing in the hub, use the SST to tap in the oil seal until it is flush with the hub end surface. 2. Apply grease to the oil seal lip.

49 F019 001
MARK

2. Remove the hub bolt using a press as necessary. Inner Bearing Outer Race, Outer Bearing Outer Race Removal Note Note D When the inner bearing outer race is removed, the inner race and oil seal are removed together.
D Remove the bearing outer race using a suitable

Hub Bolt Installation Note D Press new hub bolts into the wheel hub using a press.

round bar and a hammer. For the other side, reverse the wheel hub and remove the outer race.

CONTINUED

M–4

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TO. MODEL .INDEX

FRONT AXLE (4 2), FRONT AXLE (4 4)
Hub and Disc Plate Component Installation Note 1. Apply grease to the areas indicated in the figure.

FRONT AXLE (4 4)
WHEEL HUB, STEERING KNUCKLE INSPECTION Wheel Bearing Play Inspection (Refer to FRONT AXLE (4 2), WHEEL HUB, STEERING KNUCKLE INSPECTION, Wheel Bearing Play Inspection.) Preload Adjustment Caution D When replacing the locknut, tighten it using the SST and turn the wheel hub a few times to seat the bearing. Then, perform the preload adjustment. 1. For RFW model, remove the hub cap and drive shaft end flange. For MFW model, remove the freewheel hub component. 2. Remove the spacer and set plate. 3. Remove the brake caliper component, and suspend it by a rope. 4. Loosen the locknut to the extent that it can be turned by hand using the SST.
49 S231 635

2. Install the hub and disc plate component, then adjust the preload. (Refer to FRONT AXLE (42), WHEEL HUB, STEERING KNUCKLE INSPECTION, Preload Adjustment.)

5. Attach a pull scale to a hub bolt and measure the frictional force. 6. Tighten the locknut until the reading reaches the specified amount. Preload Frictional force plus 5.9—10.7 N {0.6—1.1 kgf, 1.4—2.4 lbf} 7. Install the set plate, spacer, freewheel hub or drive shaft end flange, hub cap and brake caliper component.

CONTINUED

M–5

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RANG.DRFT.REPAIR MANUAL PAGES. FROM. MANUAL

TO. MODEL .INDEX

FRONT AXLE (4 4)
WHEEL HUB, STEERING KNUCKLE REMOVAL/INSTALLATION 1. Remove in the order indicated in the table. 2. Install in the reverse order of removal.

55—80 {5.6—8.2, 41—59}

R SST R SST

SST

55—67 {5.6—6.9, 41—49}

54—68 {5.5—7.0}

R
30—51 {3.0—5.2, 22—37}

SST

R R SST R SST R R

R

SST SST R SST R
19—25 {1.9—2.6, 14—18} 118—156 {12—16, 87—115} 40—44 {4.0—4.5, 29—32} 45—58 {4.5—6.0, 33—43}

R

(RFW MODEL)

(MFW MODEL)
25—29 {2.5—3.0, 19—21}

N·m {kgf·m, ft·lbf}

1 2 3 4 5 6

Hub cap Drive shaft end flange Freewheel hub component Spacer Set plate Locknut + Removal Note + Installation Note Brake caliper component + FRONT AXLE (4 2), WHEEL HUB, STEERING KNUCKLE REMOVAL/INSTALLATION, Brake Caliper Component Removal Note. Hub and disc plate component

9 10

Dust cover Tie-rod end ball joint + Section N, MANUAL STEERING, STEERIG GEAR AND LINKAGE REMOVAL/ INSTALLATION, Tie-rod End Ball Joint Removal Note Disc plate + FRONT AXLE (4 2), WHEEL HUB, STEERING KNUCKLE REMOVAL/INSTALLATION, Disc Plate Removal Note Wheel hub + FRONT AXLE (4 2), WHEEL HUB, STEERING KNUCKLE REMOVAL/INSTALLATION, Wheel Hub Removal Note

11

7

12

8

CONTINUED

M–6

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FRONT AXLE (4 4)
Steering Knuckle Component Removal Note 1. Remove the lower arm ball joint from the knuckle using the SST. (Refer to section R, FRONT SUSPENSION, TORSION BAR SPRING AND LOWER ARM (4 2) REMOVAL/INSTALLATION, Lower Arm Ball Joint/Knuckle Removal Note.) 2. Remove the lower arm installation bolt and remove the lower arm with the knuckle. Oil Seal Removal Note D Remove the oil seal using a screwdriver.

13

Hub bolt + FRONT AXLE (4 2), WHEEL HUB, STEERING KNUCKLE REMOVAL/INSTALLATION, Hub Bolt Removal Note + FRONT AXLE (4 2), WHEEL HUB, STEERING KNUCKLE REMOVAL/INSTALLATION, Hub Bolt Installation Note Outer bearing inner race Oil seal + Installation Note Inner bearing inner race Inner bearing outer race + FRONT AXLE (4 2) WHEEL HUB, STEERING KNUCKLE REMOVAL/INSTALLATION, Inner Bearing Outer Race, Outer Bearing Outer Race Removal Note + Installation Note Outer bearing outer race + FRONT AXLE (4 2) WHEEL HUB, STEERING KNUCKLE REMOVAL/INSTALLATION, Inner Bearing Outer Race, Outer Bearing Outer Race Removal Note + Installation Note Nut + Section R, FRONT SUSPENSION, TORSION BAR SPRING AND LOWER ARM (4 2) REMOVAL/INSTALLATION, Nut Installation Note Shock absorber bolt Upper arm ball joint + Section R, FRONT SUSPENSION, UPPER ARM REMOVAL/INSTALLATION, Upper Arm Ball Joint/Knuckle Removal Note Steering knuckle component + Removal Note Lower arm ball joint Oil seal + Removal Note + Installation Note Spacer Needle bearing + Removal Note + Installation Note Steering knuckle

14 15 16 17

18

19

Needle Bearing Removal Note D Remove the needle bearing using the SST.
49 S231 660

20 21

22 23 24

25 26

Needle Bearing Installation Note 1. Install the needle bearing using the SST and a press. 2. Apply grease to the needle bearing.

49 S033 108

27

Locknut Removal Note D Remove the locknut using the SST.
49 S231 635

CONTINUED

M–7

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TO. MODEL .INDEX

FRONT AXLE (4 4)
Oil Seal Installation Note 1. Install the new oil seal using the SST and a press. 2. Apply grease to the oil seal lip. Locknut Installation Note 1. Install the locknut using the SST.
49 S231 635 49 S033 107

Outer Bearing Outer Race Installation Note D Install the outer bearing outer race using the SST and press.

2. Adjust the preload. (Refer to FRONT AXLE (44) WHEEL HUB, STEERING KNUCKLE INSPECTION, Preload Adjustment)

49 F027 005

Inner Bearing Outer Race Installation Note D Install the inner bearing outer race using the SST and a press.

49 F027 007

Oil Seal Installation Note D Install the new oil seal using the SST and a press.

49 S033 106

CONTINUED

M–8

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REAR AXLE

REAR AXLE
REAR AXLE INSPECTION Wheel Bearing Play Inspection 1. Jack up the rear end and support it with safety stands. 2. Verify that there is no abnormal noise and that the tire rotates smoothly when forcefully rotated by hand. 3. With a hand on top of the tire, inspect the bearing play. Wheel bearing axial play 0.05—0.25 mm {0.002—0.010 in} AXLE SHAFT REMOVAL/INSTALLATION 1. Remove in the order indicated in the table. 2. Install in the reverse order of removal.

4. If not as specified, adjust the bearing play. (Refer to REAR AXLE, AXLE SHAFT REMOVAL/INSTALLATION, Bearing Inner Race, Bearing Locknut Installation Note, Bearing play adjustment.)

SST
*

275—313 {28—32, 203—231}

SST

R

R SST

R SST SST

16—21 N·m {1.6—2.2 kgf·cm, 12—15 in·lbf}

SST R

108—127 {11—13, 80—94}

SST R

CONTINUED
*49

0259 770B
N·m {kgf·m, ft·lbf}

M–9

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REAR AXLE
Bearing Housing Removal Note D Remove the bearing and bearing housing using the SSTs.
49 S026 204 49 S026 205

1 2 3 4 5 6 7

Brake drum Parking brake connecting pin Brake pipe Nut Axle shaft and back plate component Shim Bearing locknut + Removal Note + Installation Note Lock washer Bearing housing + Removal Note Bearing inner race + Installation Note Bearing spacer Oil seal (bearing housing side) + Installation Note Bearing outer race + Removal Note + Installation Note Back plate component Axle shaft Hub bolt Baffle Oil seal (axle casing side) + Removal Note + Installation Note

49 S026 208

8 9 10 11 12 13

Bearing Outer Race Removal Note D After removing the bearing inner race and oil seal from the rear wheel hub, tap lightly using a suitable round bar to force out the outer race.

14 15 16 17 18

Bearing Locknut Removal Note Note D Be careful when removing or installing the bearing locknuts for the left wheels because they are left threaded (tightened by turning counterclockwise).
D Set the SSTs as shown in the figure, and remove

Oil Seal (Axle Casing Side) Removal Note D Remove the oil seal from the axle casing using a screwdriver.
OIL SEAL

the bearing locknut from the rear axle shaft.
AXLE CASING

49 0603 635A 49 S120 645A

Oil Seal (Axle Casing Side) Installation Note 1. Use the SST to tap the oil seal in until it is flush with the end of the axle casing. 2. After installation, apply grease to the oil seal lip.
OIL SEAL

49 H025 001

AXLE CASING

CONTINUED

M–10

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REAR AXLE
Bearing Outer Race, Oil Seal (Bearing Housing Side) Installation Note D Press the bearing outer race and the oil seal using the SSTs.
OIL SEAL BEARING OUTER RACE

49 U027 003 49 F027 004

Bearing play adjustment D Adjust the bearing play in the axial direction (only when the bearing is replaced). (1) First insert one side of the rear axle shaft component and push the end of the shaft to the thrust block, then insert a shim(s) at point A so that the clearance between the end of the shaft and the thrust block becomes 0.65—0.95 mm {0.026—0.037 in}. (2) Next insert the opposite shaft component and push the end of the shaft to the thrust block. (3) Use a shim(s) at point A so that the clearance between the end of the shaft and the thrust block becomes 0.05—0.25 mm {0.002—0.010 in}. Bearing play in axial direction 0.05—0.25 mm {0.002—0.010 in}

Bearing Inner Race, Bearing Locknut Installation Note Caution D The torque wrench must be attached perpendicular to the SST.

PINION SHAFT A SHIM THRUST BLOCK

1. Set the SST and then press the bearing inner race in until 3 to 5 threads of the bearing locknut mounting screw of the axle shaft are visible above the top of the bearing outer race.

49 S120 748

2. Remove the SST, and then install the bearing locknut to the axle shaft. 3. Tighten the bearing locknut using the SST to press in the bearing inner race. 4. Remove the SST and install the lock washer so that its tab fits into the groove of the axle shaft. 5. Tighten the bearing locknut to the specified torque. Bearing locknut tightening torque 275—313 N·m {28.0—32.0 kgf·m, 203—231 ft·lbf}

49 0603 635A 49 S120 645A

CONTINUED

M–11

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DRIVE SHAFT

DRIVE SHAFT
DRIVE SHAFT REMOVAL/INSTALLATION 1. Remove in the order indicated in the table. 2. Install in the reverse order of removal.

R

1

Wheel hub, steering knuckle + FRONT AXLE (4 4), WHEEL HUB, STEERING KNUCKLE REMOVAL/INSTALLATION Drive shaft + Removal Note + Installation Note

3 4

Snap ring Clip + Installation Note

2

Drive Shaft Removal Note Caution D Do not damage the dust cover or oil seal.
D Remove the drive shaft by prying with a bar

Clip Installation Note Left side D Install a new clip to the output shaft clip groove with the opening facing upward. Right side D Install a new clip to the clip groove of the drive shaft end with the opening facing upward.
CLIP

inserted between the differential casing and the drive shaft.

OPENING 28 mm {1.1 in}

Drive Shaft Installation Note D Be careful not to damage the oil seal with the shaft spline when installing the drive shaft.

CONTINUED

M–12

TO. Assemble in the reverse order of removal. FROM. MODEL .REPAIR MANUAL PAGES.INDEX DRIVE SHAFT DRIVE SHAFT DISASSEMBLY/ASSEMBLY 1. Disassemble in the order indicated in the table.CHAPTER.BACK.DRFT.INDEX RANG. R RIGHT SIDE R R R R R LEFT SIDE 1 Boot band + Disassembly Note + Assembly Note Clip Outer ring + Disassembly Note + Assembly Note Snap ring + Assembly Note Balls + Disassembly Note + Assembly Note 6 Inner ring + Disassembly Note + Assembly Note Cage + Disassembly Note + Assembly Note Boot + Disassembly Note + Assembly Note Bell joint component Drive shaft 2 3 7 8 4 5 9 10 CONTINUED M–13 . 2. MANUAL TO.

inner ring. 30_ Boot Disassembly Note Note D The wheel side boot does not need to be removed unless it is being replaced.INDEX DRIVE SHAFT Boot Band Disassembly Note Note D The wheel side boot band does not need to be removed unless replacing it.TO.BACK. 2. 2.REPAIR MANUAL PAGES.9 in} WHEEL SIDE DIFFERENTIAL SIDE MARKS 2. Cage Disassembly Note Caution D Mark with paint. Remove the boot. 1. Disassemble the balls. 4. 2. Mark the cage and outer ring for proper assembly.DRFT. Remove the clip using a screwdriver. CONTINUED M–14 . Disassemble the snap ring from the drive shaft using a snap-ring pliers. Mark the drive shaft and inner ring for proper assembly. new boot bands. 3. 100. Remove the outer ring from the inner ring and the balls. Inner Ring. Slide the boot along the shaft to expose the joint. 4. 2. 1.5 mm {4. assemble the boot.0 in} 99. 1. FROM.INDEX RANG. 3. Balls. and differential side boot to the drive shaft. 3. 1. Remove the tape. Turn the cage by approximately 30 degrees and pull the cage and balls away from the inner ring. do not use a punch. TAPE Boot Assembly Note Note D The wheel side and differential side boots are different. Outer Ring Disassembly Note Caution D Mark with paint. With the splines of the shaft still wrapped in tape from disassembly. cage from the drive shaft as component.CHAPTER. MANUAL TO. MARKS 1.2 mm {3. Wrap the shaft splines with tape. Temporarily assemble the wheel side boot. do not use a punch. MODEL . Clean the grease away. Pry up the locking clip using a screwdriver and remove the band using pliers.

Snap Ring Assembly Note 1. CONTINUED M–15 . Apply grease to the inside of the boot.4—24. Release trapped air from inside the boot using a screwdriver covered with a rag. SNAP RING GROOVE INNER RING Outer Ring Assembly Note Note D Use the specified grease supplied in the boot kit. balls. MODEL . Install a new snap ring.6 oz} Differential side : 95—105 g {3. Boot Band Assembly Note Caution D Do not damage the boot. 1.INDEX DRIVE SHAFT Cage.BACK. 2. Set the new boot band to the boot groove.INDEX RANG. 6. MARKS 4. the drive shaft may become disengaged. Fold the band back and use pliers to pull it tight. Inner Ring. and install the outer ring onto the shaft. FROM. D For wheel side. Balls.0 mm {21. 1. Install a new clip. Align the marks. Lock the end of the band by bending the locking clips. Align the marks. and install the balls and cage to the inner ring in the direction shown in the figure. BALLS CAGE LEFT SIDE RIGHT SIDE Standard length Right side : 619.7—22.4—3. If incorrectly installed. 2.8—4.7 in} Left side : 551. Wheel side : 110—130 g {3.REPAIR MANUAL PAGES. 3.TO.0—629.0—561.0 in} 3.0 mm {24. Apply grease to the cage. apply grease only when assembling the boot.7 oz} 2. MANUAL TO. 5. Caution D Install the cage with the offset facing the snap ring groove.DRFT. Set the drive shaft to the standard length.CHAPTER. inner ring. and the outer ring.

37—57 {3. ft·lbf} 1 Drive shaft + DRIVE SHAFT. 27—39} N·m {kgf·m.INDEX RANG. MANUAL TO. FROM.REPAIR MANUAL PAGES.7—5. Remove in the order indicated in the table.INDEX DRIVE SHAFT OUTPUT SHAFT (MFW) REMOVAL/INSTALLATION 1.TO. 2.BACK.CHAPTER. DRIVE SHAFT REMOVAL/ INSTALLATION Bolt 3 4 Screw Output shaft component + Removal Note 2 Output Shaft Component Removal Note D Remove the output shaft by prying with a bar inserted between the bearing housing of the output shaft and the differential casing. Install in the reverse order of removal. CONTINUED M–16 . MODEL .DRFT.5.

R SST R R R R 1 Clip + DRIVE SHAFT.CHAPTER.INDEX DRIVE SHAFT OUTPUT SHAFT DISASSEMBLY/ASSEMBLY 1. MANUAL TO.BACK. CONTINUED M–17 . DRIVE SHAFT REMOVAL/ INSTALLATION. 2.REPAIR MANUAL PAGES. Clip Assembly Note Output shaft component + Disassembly Note + Assembly Note Oil seal + Assembly Note 4 Bearing + Disassembly Note + Assembly Note Output shaft Bearing housing Oil seal + Assembly Note O-ring 2 5 6 7 8 3 Output Shaft Component Disassembly Note D Disassemble the output shaft component using a press. MODEL . Assemble in the reverse order of disassembly.INDEX RANG. FROM.TO. Disassemble in the order indicated in the table.DRFT.

D Press the new bearing to the output shaft.BACK. MODEL .DRFT. 49 M005 796 Output Shaft Component Assmebly Note D Press the output shaft and bearing to the bearing housing.REPAIR MANUAL PAGES. MANUAL TO.TO.INDEX RANG. Oil Seal Assembly Note D Assemble the new oil seal by lightly tapping it using a plastic hammer.CHAPTER. CONTINUED M–18 . Oil Seal Assembly Note D Use the SST to assemble the new oil seal until it is flush with the bearing housing end using the SST. FROM.INDEX DRIVE SHAFT Bearing Disassembly Note D Remove the bearing from the output shaft component using a press. Bearing Assembly Note Caution D Press the bearing center and shaft center vertically.

Install a new washer and the drain plug.0—5. 29—39 ft·lbf} FILLER PLUG WASHER 3.48 US qt.INDEX RANG. 1. SAE 90 Capacity: 4 2: 1. FROM. Tightening torque 40—53 N·m {4.23 lmp qt} 4 4: 1. 1. 29—39 ft·lbf} 5. Tightening torque 40—53 N·m {4. Remove the filler and drain plugs.63 lmp qt} 6. If it is low. Add the specified oil from the filler plug hole until it reaches the brim of the hole. Verify that the oil is at the brim of the filler plug hole. 1.23 lmp qt} 4 4: 1.DRFT.0—5. Specified oil Type Standard differential: API service GL–5.5 kgf·m.40 L {1. Install a new washer and the filler plug.63 lmp qt} Specified oil Type Standard differential: API service GL–5. SAE 90 LSD: API service GL–6. 2. Remove the filler plug.48 US qt.40 L {1.96 US qt. 1.96 US qt.85 L {1.5 kgf·m. Wipe the plugs clean. CONTINUED M–19 .REPAIR MANUAL PAGES. 3. MANUAL TO. Install a new washer and the filler plug.INDEX REAR DIFFERENTIAL REAR DIFFERENTIAL REAR DIFFERENTIAL OIL INSPECTION Caution D Position the vehicle level.BACK. SAE 90 LSD: API service GL–6.0—5.CHAPTER. 4.85 L {1. MODEL . Drain the differential oil into a container. add the specified oil. 1.5 kgf·m. Tightening torque 40—53 N·m {4. 29—39 ft·lbf} REAR DIFFERENTIAL OIL REPLACEMENT 1.TO. 2. SAE 90 Capacity 4 2: 1.

ft·lbf} 1 Axle shaft and back plate component + REAR AXLE. MANUAL TO. Remove the rear propeller shaft.6—2. AXLE SHAFT REMOVAL/ INSTALLATION 2 Differential + Removal Note Differential Removal Note D To prevent the differential from dropping. Remove in the order indicated in the table.BACK. REAR PROPELLER SHAFT REMOVAL/INSTALLATION.TO.9. (Refer to section L. 19—20} 50—58 {5. FROM. 4. Then hit the differential carrier using a wooden hammer.CHAPTER.INDEX REAR DIFFERENTIAL REAR DIFFERENTIAL REMOVAL/INSTALLATION Caution D Clean away the old sealant before applying the new sealant. D Install the differential carrier within 10 minutes after applying sealant.) 3. REAR DIFFERENTIAL OIL REPLACEMENT.INDEX RANG. 37—43} N·m {kgf·m. 26—28 {2. (Refer to REAR DIFFERENTIAL. MODEL .DRFT.) 2. CONTINUED M–20 . Drain the differential oil.0—6. D Allow the sealant to set at least 30 minutes after installation before filling the differential with the specified oil.0. 1.REPAIR MANUAL PAGES. Install in the reverse order of removal. leave the two bolts loosely tightened. REAR PROPELLER SHAFT (44).

SST SST SST SST SST 1 2 3 4 5 6 7 8 9 10 11 12 13 Differential component + Disassembly Note Bearing cap + Disassembly Note Adjusting shim Side bearing cup Side bearing cone + Disassembly Note Pinion nut + Disassembly Note Companion flange + Disassembly Note Oil seal + Disassembly Note Thrust washer Drive pinion + Disassembly Note Front bearing cone Collapsible spacer Rear bearing cone + Disassembly Note 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 Adjusting shim Front bearing cup + Disassembly Note Oil buffle Rear bearing cup + Disassembly Note Carrier Hex screw Ring gear Roll pin + Disassembly Note Pinion shaft Thrust block Pinion gear Pinion gear thrust washer Side gear Side gear thrust washer Case CONTINUED M–21 .TO.REPAIR MANUAL PAGES. MANUAL TO.DRFT. MODEL . FROM.BACK.CHAPTER.INDEX RANG.INDEX REAR DIFFERENTIAL STANDARD DIFFERENTIAL DISASSEMBLY D Disassemble in the order indicated in the table.

It can strike legs or feet and may cause serious injury. do not allow differential component to fall.BACK.INDEX REAR DIFFERENTIAL Differential Component Disassembly Note D Mount a carrier component to the SST or equivalent. MARK Companion Flange Disassembly Note D Remove the companion flange using universal puller. FROM. D Remove the side bearing cone using a press and Oil Seal Disassembly Note D Pull out the oil seal using the SST. T57L–500–B Pinion Nut Removal Note D Hold the companion frange and remove the pinion nut.INDEX RANG.REPAIR MANUAL PAGES.CHAPTER. MODEL . Drive Pinion Disassembly Note D Remove the drive pinion by tapping with a plastic hammer. 308–047 T77F–1102–A the SST.TO. Bearing Cap Disassembly Note D Place a mark on one of the bearing caps so that the left and right bearing caps won’t get mixed up. MANUAL TO. Side Bearing Cone Disassembly Note Warning D When pulling the side bearing cone. 205–D064 D84L–1123–A CONTINUED M–22 . Use the mark for matching at the time of assembly.DRFT. Caution D Mark the left bearing in order to install in the same position.

TO. 3308–047 T77F–1102–A Knock Pin Disassembly Note Caution • Insert the bar from the knock pin hole at the opposite side from where the ring gear is installed. • Remove the bearing outer races by using the two grooves on the carrier and tapping the outer races alternately.INDEX RANG.DRFT. MODEL . D Secure the gear case in a vise and remove the roll pin using a small drift. 100–001 T50T–100–A Front Bearing Outer Race. D Remove the bearing races using the SSTs (308 047 T77F–1102A and 100 001 T50T–100–A). CONTINUED M–23 . D Remove the rear bearing cone using the SST. • Secure the gear case in a vise and remove the knock pin by using a 4 mm {0.16 in} diameter bar.INDEX REAR DIFFERENTIAL Rear Bearing Cone Disassembly Note Note D Mark or otherwise distinguish between the front and rear cones so that they are not mixed up at the time of reassembly.BACK. MANUAL TO.REPAIR MANUAL PAGES. Rear Bearing Cup Disassembly Note Note D Mark or otherwise distinguish between the front and rear cups so that they are not mixed up at the time of reassembly. 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.CHAPTER. Roll Pin Disassembly Note Caution D Insert the bar from the knock pin hole at the opposite side from where the ring gear is installed. FROM. 205–D064 D84L–1123–A Front Bearing Cup.

INDEX REAR DIFFERENTIAL STANDARD DIFFERENTIAL ASSEMBLY D Assemble in the order indicated in the table.6—9.TO.REPAIR MANUAL PAGES.3.BACK. ft·lbf} 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 Case + Assembly Note Side gear thrust washer + Assembly Note Side gear Pinion gear thrust washer Pinion gear Thrust block Pinion shaft Roll pin Ring gear Hex screw Side bearing cone + Assembly Note Carrier Oil buffle Front bearing cup + Assembly Note Rear bearing cup + Assembly Note 16 17 18 19 20 21 22 23 24 25 26 27 Adjusting shim + Assembly Note Rear bearing cone + Assembly Note Drive pinion + Assembly Note Collapsible spacer Front bearing cone Thrust washer Oil seal + Assembly Note Companion flange Pinion nut Side bearing cup + Assembly Note Adjusting shim + Assembly Note Bearing cap + Assembly Note CONTINUED M–24 . 96—110} SST R SST R R R R SST 298—500 {30.DRFT.INDEX RANG.9. MODEL . 220—368} N·m {kgf·m. FROM. 55—70} SST R SST SST R R R SST 130—150 {13. MANUAL TO.3—50.2—15.CHAPTER.7. 75—95 {7.

This measurement is the thickness needed for the selective shim if there was no marking on the drive pinion.7 kgf·m.3 kgf·cm. 2. If the drive pinion is marked with a plus (+) reading. 5. Center the SST (205–456) into the side bearing bore. T76P–4020–A10 and 205–456).INDEX RANG. collapsible spacer and companion flange to the carrier. 205–110.2—1.2 in·lbf} 3. T76P–4020–A11 Drive Pinion Assembly Note Drive pinion preload adjustment Caution D Never loosen pinion nut to decrease drive pinion preload torque.5 N·m {12.2—15.BACK.TO. Continue to tighten in small increments until the specified preload can be obtained.6—13. the amount marked should be subtracted from the feeler gauge measurement. Tightening torque 75—95 N·m {7. MODEL . 3. If preload torque is exceeded.6—9. 2. Install the drive pinion. MANUAL TO. Insert the thickest feeler gauge possible between the SSTs (205–110. 55—70 ft·lbf} Note D There should be drag on the feeler gauge when it is inserted between the SSTs (205–110. a new collapsible spacer must be installed and the torque sequence repeated.8 kgf·m. and tighten the pinion nut until all end play is removed. Roll the SST component back and forth a few times to seat the bearings while tightening the SST by hand. 205–456 6.INDEX REAR DIFFERENTIAL Adjusting Shim Assembly Note Pinion height Adjustment 1. the amount marked should be added to the feeler gauge measurement. Rear Bearing Cone Assembly Note D Assemble the selected spacer on the drive pinion and press the rear bearing inner race until it is firmly seated on the shaft. 10. Assemble the front bearing cone into the front bearing cup and assemble the SSTs. T76P–4020–A10 and 205–456). T76P–4020–A10 205–457 205–105. 20 ft·lbf} 4. T76P–4020–A9 205–111.CHAPTER. If the drive pinion is marked with a minus (–) reading. Tightening torque 27 N·m {2. FROM.DRFT. 205–110 T76P–4020–A10 FEELER GAUGE 205–456 CONTINUED M–25 . T76P–4020–A3 205–090 T75L–1165–B 205–109. Assemble the rear bearing cone over the SST and insert it into the rear bearing cup of the carrier. Drive pinion preload 1. and never exceed specified preload torque. If the specified preload can’t be obtained within the specified tightening torque range. 1.REPAIR MANUAL PAGES. Install the bearing caps and tighten the bolt. replace the collapsible spacer and inspect again.

Standard backlash 0—0. D Press the side bearings into the gear case using 205–007 T56T–4676–B the SST. Install the outer bearing cup and inner bearing cup using the SST. thrust block. Oil Seal Assembly Note 1. use the thrust washers to adjust.004 in} (4) If the backlash exceeds the standard.INDEX REAR DIFFERENTIAL Case Assembly Note D Assemble the side gears. 90° intervals and mount a dial indicator to the carrier so that the feeler comes in contact at a 90° angle with one of the ring gear teeth. Side Bearing Cone Assembly Note Caution D Bearings should be assembled to the original positions.DRFT.CHAPTER. Bearing Cap Assembly Note Ring gear backlash adjustment 1. Install the oil baffle in the outer bearing cup bore of the carrier. (1) Mark the ring gear at four points at approx. MANUAL TO. Divide the amount of shim in step 2 appropriately between the right and left side. make a crimp so that the pin will not come out of the gear case. pinion shaft and knock pin. Push the gear case component to the left side of the carrier and measure the clearance between the side bearing and carrier. Adjusting Shim. Rear Bearing Cup Assembly Note 1.TO. CONTINUED M–26 . Adjust the drive pinion. Assemble the new oil seal using the SST.1 mm {0—0. 2. pinion gears. 2. then install the bearing cap. MODEL .INDEX RANG. 205–024 T76P–4616–A Side Gear Thrust Washer Assembly Note D Adjust the backlash of the side gears and pinon gear as follows. Front Bearing Cup. 205–092 T75L–1165–DA Side Bearing Cup.BACK. Install the gear case component on the carrier. 3. After assembling the knock pin. FROM. (3) Move the pinion gear and measure the backlash at the end of the pinion gear. ring gear backlash and the side bearing preload as follows.REPAIR MANUAL PAGES. Apply a light coat of oil to the lip of a new oil seal. (2) Secure one of the side gears. This measurement is the left and right total shim thickness. 2. (1) Set a dial gauge to the pinion gear as shown in the figure. thrust washer. 4.

08 mm {0. If the backlash is within specification but the rotating torque is to high. If backlash is not as specified. the preload may be adjusted by removing an equal amount of shims from both sides of the differential.TO.12 mm {0.CHAPTER.4 N·m {24. then adjust the backlash. adjust the pinion height. MODEL . CONTINUED M–27 . (1) Coat both surfaces of 6—8 teeth of the ring gear uniformly with a thin red lead coating. rotate the drive pinion several times and inspect the tooth contact. Using a torque wrench.005 in} and difference of the maximum and minimum backlash value is less than 0. 8. wipe off the red lead coating. 20.003 in}. Inspect the drive pinion and ring gear tooth contact. MANUAL TO.BACK. FROM. (2) While moving the ring gear back and forth by hand.INDEX REAR DIFFERENTIAL DIAL INDICATOR WITH BRACKETRY RING GEAR 5.REPAIR MANUAL PAGES.INDEX RANG. (3) If the tooth contact is good.0 kgf·cm. (4) If it is not good. correct the backlash by switching shims from one side of the differential case to the other. and then reading the rotating torque. inspect the total rotating torque of the pinion and differential component by rotating the pinion three complete revolutions.8 in·lbf}. 7. The readings should not exceed 2. 6. Inspect the backlash at the three other marked points and make sure that the minimum backlash is more than 0.DRFT.

Jack up the vehicle and support it on safety stands. Set the freewheel hub control handle to the “FREE” position.REPAIR MANUAL PAGES.INDEX RANG.INDEX MANUAL FREEWHEEL (MFW) MECHANISM REMOTE FREEWHEEL (RFW) MECHANISM MANUAL FREEWHEEL (MFW) MECHANISM ON-VEHICLE INSPECTION 1. Set the freewheel hub control handle to “LOCK” position and inspect that the wheel turns with considerable force applied to make it turn. 5. Jack up the vehicle and support it on safety stands. FROM. 2. If not as specified. MODEL . If not correct.BACK. Continuity Yes No Switch Depressed (ON) Released (OFF) 4. 3. Remove the transfer case switch (4 4 indicator switch). TRANSFER NEUTRAL SWITCH INSPECTION 1. Jack up the front of the vehicle and support it on safety stands. 2.TO. Set the select lever in “2H” position. 2. CONTINUED M–32 . and inspect that it turns smoothly. 3. Inspect for continuity between the terminals as shown using an ohmmeter. Remove the transfer case switch (neutral switch). REMOTE FREEWHEEL (RFW) MECHANISM 4 4 INDICATOR SWITCH INSPECTION 1. MANUAL TO. then turn the handle clockwise and counterclockwise by hand. 4. replace the switch.CHAPTER.DRFT. replace the freewheel hub component as necessary.

) 2.REPAIR MANUAL PAGES. METER HOOD REMOVAL/INSTALLATION. Remove the RFW main switch. DASHBOARD AND CONSOLE. Disconnect the RFW switch connector and remove the switch.CHAPTER. FROM.512 in} À 1 RFW main switch 2.472 in} 13 mm {0. 4.TO.INDEX REMOTE FREEWHEEL (RFW) MECHANISM 1. MANUAL TO. If not correct. Remove the meter hood. MODEL . Inspect for continuity between the terminals as shown using an ohmmeter. : Continuity Switch OFF ON Terminal A B D F 3. Inspect for continuity at the switch using an ohmmeter. Jack up the vehicle and support it on safety stands. If not correct. replace the switch. Continuity Yes No Switch Depressed (ON) Released (OFF) RFW MAIN SWITCH REMOVAL/INSTALLATION 1. replace the switch. Continuity Yes No Switch Depressed (ON) Released (OFF) 123456567 3. replace the switch. OFF ON 12 mm {0. RFW SWITCH INSPECTION 1. 2. 2.BACK. If not correct. 3. RFW MAIN SWITCH INSPECTION 1.INDEX RANG. (Refer to Section S. Remove in the order indicated in the table. Inspect for continuity at the switch using an ohmmeter.DRFT. CONTINUED M–33 . Install in the reverse order of removal.

FROM. CONTINUED M–34 . Disconnect the vacuum hoses from the actuator. Connect the vacuum pump tester to the actuator (lock side) as shown. Blow through A and inspect that air flows from B. Remove the one–way check valve. 3. 6. MODEL .66 kPa {200 mmHg.INDEX RANG. B A 8. Inspect that air flows from the air filter. Disconnect the vacuum pump tester. If not correct. replace the solenoid valve(s). If not correct. B A RFW ACTUATOR INSPECTION 1.CHAPTER. 7. Disconnect the vacuum hoses and the connector from each solenoid valve. 7. Apply 26. BLOW B 5. 3. and verify that the rod moves toward the left (driver’s side). Jack up the vehicle and support it on safety stands. 4. Blow through B and inspect that air does not flow from A. 7. Apply 26. LOCK AND FREE SOLENOID VALVES INSPECTION 1.87 inHg} vacuum.REPAIR MANUAL PAGES. replace the one–way check valve. replace the actuator. 3. 2. Connect a vacuum pump tester to the actuator (free side) as shown. If not correct. 7. 2. Blow through each valve from port B. 5. A AIR FILTER 4.INDEX REMOTE FREEWHEEL (RFW) MECHANISM ONE–WAY CHECK VALVE INSPECTION 1.87 inHg} vacuum. Blow through each valve from port B. 2. and inspect that the rod moves toward the right (passenger side).BACK. 4.66 kPa {200 mmHg. MANUAL TO. 6. Connect 12V and a ground to the terminals of each valve. Inspect that air flows from port A.TO.DRFT.

(Refer to section S. RFW CONTROL MODULE 4. Remove the scuff plate. TRIM. Remove the front side trim. and/or RFW control module. Remove the scuff plate.CHAPTER. SCUFF PLATE REMOVAL/INSTALLATION. FRONT SIDE TRIM REMOVAL/INSTALLATION.REPAIR MANUAL PAGES. FRONT SIDE TRIM REMOVAL/INSTALLATION.DRFT. (Refer to section S.) 3. (Refer to section S. If not correct.BACK. 1 2 3 4 Connector Nut Bolt RFW control module CONTINUED M–35 . Remove in the order indicated in the table. MODEL . (Refer to section S.INDEX RANG. TRIM. FROM. TRIM. replace the component(s). Remove the front side trim.TO. TRIM.) 2.INDEX REMOTE FREEWHEEL (RFW) MECHANISM RFW CONTROL MODULE INSPECTION 1. MANUAL TO. wiring. Turn the ignition switch on and inspect the RFW control module terminal voltages. Install in the reverse order of removal.) 3. SCUFF PLATE REMOVAL/INSTALLATION. referring to the Terminal Voltage Chart. 4. REW CONTROL MODULE REMOVAL/INSPECTION 1.) 2.

5 V B+ Below 0.DRFT.INDEX RANG.5 V B+ Below 0.5 V Below 0.CHAPTER.5 V – D Harness (4 Condition Solenoid OFF Voltage B+ Below 0. . Fuse ( (Battery-Ignition y g switch—RFW CM) D Harness (RFW main I RFW main switch RFW main switch switch—RFW switch RFW CM) D RFW main switch D Harness ( (RFW switch—RFW CM) ) D RFW switch D Harness (4 J RFW switch RFW switch K 4 4 indicator switch 4 4 indicator switch 4 indicator switch—RFW switch RFW CM) D 4 4 indicator switch D Harness (Transfer neutral L Transfer neutral switch Transfer neutral switch switch—RFW switch RFW CM) D Transfer neutral switch CONTINUED M–36 .REPAIR MANUAL PAGES. MODEL .5 V B+ CM) Inspection point D Harness (Lock solenoid—RFW D Lock solenoid – Solenoid OFF Harness to ground point D Harness (Free solenoid—RFW CM) D Free solenoid – 4 indicator light RFW CM) light—RFW D 4 4 indicator light D Harness (Lock indicator F light RFW CM) light—RFW D Lock indicator light H Harness. FROM.5 V Below 0.TO. MANUAL TO.5 V B+ Below 0.5 V B+ Below 0.BACK.5 V B+ Below 0.5 V B+ Below 0.INDEX REMOTE FREEWHEEL (RFW) MECHANISM Terminal Voltage Chart RFW CONTROL MODULE TERMINAL B+: Battery positive voltage Terminal A B C D E Signal name Lock solenoid Ground Free solenoid – 4 4 indicator light Lock indicator light Battery Connected to Lock solenoid Solenoid ON Body Free solenoid Solenoid ON – 4 4 indicator light LOCK indicator light Battery – 4 4 indicator light OFF 4 4 indicator light ON Lock indicator light OFF Lock indicator light ON Ignition swtich ON Ignition swtich OFF RFW main switch released (OFF) RFW main switch depreased (ON) RFW switch OFF RFW switch ON 4 4 indicator switch OFF 4 4 indicator switch ON Transfer neutral switch OFF Transfer neutral switch ON B+ Below 0.

17—19} R SST 37—53 {3.7—5. FROM. control box component Gear sleeve Output shaft + Removal Note 2 3 Output Shaft Removal Note D Remove the output shaft using the SST. MODEL . 27—39} N·m {kgf·m.) 2. Drain the front differential oil.REPAIR MANUAL PAGES.5.7.5.CHAPTER. ft·lbf} 1 Drive shaft + DRIVE SHAFT.3—2. MANUAL TO. Install in the reverse order of removal.TO.7—5.INDEX REMOTE FREEWHEEL (RFW) MECHANISM JOINT SHAFT COMPONENT REMOVAL/INSTALLATION 1.BACK. Remove in the order indicated in the table. (Refer to FRONT DIFFERENTIAL. 49 0813 215A CONTINUED M–37 .INDEX RANG. DRIVE SHAFT REMOVAL/ INSTALLATION Vacuum hose RFW switch connector 4 5 6 7 Snap pin Joint shaft component. 23—26 {2.DRFT. 3. 27—39} 37—53 {3. DIFFERENTIAL OIL REPLACEMENT.

DRFT.REPAIR MANUAL PAGES.INDEX RANG.TO.CHAPTER. MODEL .INDEX REMOTE FREEWHEEL (RFW) MECHANISM JOINT SHAFT COMPONENT DISASSEMBLY D Disassemble in the order indicated in the table.BACK. FROM. SST SST SST 1 2 3 4 5 6 7 8 Control box Clip Remote freewheel hub + Disassembly Note Spacer Retaining ring Ball bearing + Disassembly Note Adjustment shim (s) Dust seal 9 10 11 12 13 14 15 Bearing + Disassembly Note Oil seal + Disassembly Note Joint shaft Needle bearing Clip Casing Output shaft and gear sleeve CONTINUED M–38 . MANUAL TO.

0012 in} 2. MODEL .INDEX RANG. Remove the ball bearing using a press.DRFT.BACK. replace the joint shaft. MANUAL TO.INDEX REMOTE FREEWHEEL (RFW) MECHANISM Remote Free Wheel Hub Disassembly Note D Remove the remote free wheel hub using the SST. Measure the joint shaft runout. Oil Seal Disassembly Note D Remove the oil seal using the SST.TO. Maximum runout 0. FROM.CHAPTER. 2. 49 W027 001 CONTINUED M–39 . 49 0710 520 49 U027 004 Ball Bearing Disassembly Note 1. Remove the ball bearing and the joint shaft using a press. JOINT SHAFT INSPECTION 1. Bearing Disassembly Note D Remove the dust seal and bearing using the SST and a suitable bar.03 mm {0.REPAIR MANUAL PAGES. If not correct.

REPAIR MANUAL PAGES. ft·lbf} 1 2 3 4 5 6 7 8 Output shaft and gear sleeve Casing Oil seal + Assembly Note Adjustment shim(s) + Assembly Note Ball bearing + Assembly Note Joint shaft + Assembly Note Bearing + Assembly Note Retaining ring 9 10 11 12 13 14 15 Spacer + Assembly Note Remote freewheel hub + Assembly Note Clip Dust seal + Assembly Note Needle bearing Clip Control box CONTINUED M–40 . FROM.TO.DRFT.INDEX RANG. MANUAL TO. MODEL .6—2. 12—16} SST SST SST R R R SELECTIVE SST SELECTIVE SST R R SST R SST N·m {kgf·m .CHAPTER.INDEX REMOTE FREEWHEEL (RFW) MECHANISM JOINT SHAFT COMPONENT ASSEMBLY D Assemble in the order indicated in the table.3. 16—22 {1.BACK.

15 mm {0.50 mm {0. Remove the retaining ring.REPAIR MANUAL PAGES. 49 U027 006 Bearing Assembly Note D Install the bearing using the SSTs and a press. CONTINUED M–41 .BACK.CHAPTER.0059 in}. 0. 49 U027 006 49 U027 006 Ajustment Shim(s). Remote FreeWheel Hub Assembly Note 1.DRFT.0059 in} Available shim thickness 0.INDEX RANG. Use no more than two shims on either side. 49 U027 005 4. Maximum clearance 0.0157 in}. Measure the clearance between the remote freewheel hub and the clip. Joint Shaft Assembly Note D Install the joint shaft using the SST and a press. Measure the clearance between the ball bearing and the retaining ring. Install the new oil seal using the SST and a press.15 mm {0. 0.35 mm {0. Apply differential oil to a new oil seal. 0. 2. 3. Ball Bearing Assembly Note 1. Spacer. 49 U027 005 49 U027 006 2. Install the removed shim(s) and the ball bearing using the SST and a press. adjust by adding or removing shims.40 mm {0.0197 in} 5.TO. Install the removed spacer and the remote freewheel hub using a suitable pipe and the SST and a press. Install a new retaining ring. MODEL . If not as specified. 0. 2. MANUAL TO.30 mm {0.INDEX REMOTE FREEWHEEL (RFW) MECHANISM Oil Seal Assembly Note 1.0118 in}. Install a new clip. FROM.0138 in}. 3.

Drain the front differential oil. 12—16} Â N·m {kgf·m .3. 17—19} Á À 16—22 {1. 0. ft·lbf} 1 2 3 Vacuum hose RFW switch connector Control box CONTINUED M–42 . 0. Install the new dust seal using the SST and a press. FROM.40 mm {0. 0.CHAPTER.0197 in} Dust Seal Assembly Note 1. Remove in the order indicated in the table.3—2.0157 in}.15 mm {0.0138 in}. MODEL . If not as specified.TO.REPAIR MANUAL PAGES.INDEX RANG. MANUAL TO.BACK. (Refer to FRONT DIFFERENTIAL. adjust by adding or removing spacers.30 mm {0.50 mm {0. 23—26 {2.DRFT. Use no more than two spacers on either side.0118 in}.) 2. FRONT DIFFERENTIAL OIL REPLACEMENT.6—2. 49 M005 796 CONTROL BOX REMOVAL/INSTALLATION 1.7. Install in the reverse order of removal.0059 in}. 0.15 mm {0.INDEX REMOTE FREEWHEEL (RFW) MECHANISM 4. Maximum clearance 0. 3.35 mm {0.0059 in} Available shim thickness 0.

DRFT. FROM.CHAPTER.REPAIR MANUAL PAGES.BACK. MODEL .INDEX RANG. ft·lbf} 1 2 3 4 5 6 7 8 Snap pin Washer RFW actuator RFW switch and washer Spring cap Spring and ball Washer Roll pin + Disassembly Note + Assembly Note 9 10 11 12 13 Change rod Shift fork Boot + Assembly Note Oil seal + Assembly Note Control box CONTINUED M–43 . Disassemble in the order indicated in the table.TO.INDEX REMOTE FREEWHEEL (RFW) MECHANISM CONTROL BOX DISASSEMBLY/ASSEMBLY 1. Assemble in the reverse order of disassembly. R R R R SST R R N·m {kgf·m . 2. MANUAL TO.

1—0. 3.TO.CHAPTER. SHIFT FORK INSPECTION 1. replace the output shaft and gear sleeve as necessary.INDEX REMOTE FREEWHEEL (RFW) MECHANISM Roll Pin Disassembly Note D Remove the roll pin as shown in the figure. If not correct.40 mm {0. Measure the clearance between the gear sleeve and the shift fork. 49 U027 007 2. Inspect the output shaft and gear sleeve of the splines for damage and wear. MANUAL TO.DRFT.50 mm {0.0197 in} Oil Seal Assembly Note D Install a new oil seal using the SST and a press.0157 in} Maximum clearance 0. Standard clearance 0. CONTINUED M–44 .0040—0. MODEL . FROM.REPAIR MANUAL PAGES.INDEX RANG.BACK. Roll Pin Assembly Note D Install a new roll pin as shown in the figure. Boot Assembly Note D Install the boot as shown in the figure.

Drive Shaft Installation Note.) 6.) 2.INDEX FRONT DIFFERENTIAL FRONT DIFFERENTIAL FRONT DIFFERENTIAL OIL INSPECTION (Refer to REAR DIFFERENTIAL.3 US qt. REAR DIFFERENTIAL OIL INSPECTION.REPAIR MANUAL PAGES. SAE 90 Below –18 °C {0 °F}: API GL–5. Drain the differential oil.3 lmp qt} FRONT DIFFERENTIAL OIL SEAL REPLACEMENT 1. (Refer to DRIVE SHAFT.1 lmp qt} RFW: 1.) 3. MANUAL TO. 4. 49 G030 795 5. 1. FROM. 1. (Refer to FRONT DIFFERENTIAL. Drive shaft removal Note.3 lmp qt} FRONT DIFFERENTIAL OIL REPLACEMENT (Refer to REAR DIFFERENTIAL.INDEX RANG. DRIVE SHAFT REMOVAL/INSTALLATION.2 L {1. REAR DIFFERENTIAL OIL REPLACEMENT.CHAPTER. (Refer to REAR DIFFERENTIAL.6 US qt.5 L {1. Add the differential oil to the specified level. DRIVE SHAFT REMOVAL/INSTALLATION. SAE 90 Below –18 °C {0 °F}: API GL–5.) Specified oil Type Above –18 °C {0 °F}: API GL–5. MODEL . SAE 80 Capacity MFW: 1. 1.TO. (Refer to DRIVE SHAFT.3 US qt.5 L {1.1 lmp qt} RFW: 1.) CONTINUED M–45 .6 US qt.2 L {1.DRFT. FRONT DIFFERENTIAL OIL REPLACEMENT. Remove the drive shaft. Tap in the new oil seal to the differential using the SST.BACK. Remove the oil seal using a screwdriver. REAR DIFFERENTIAL OIL REPLACEMENT. Install the drive shaft. SAE 80 Capacity MFW: 1.) Specified oil Type Above –18 °C {0 °F}: API GL–5. 1.

MFW APPLY SCREW LOCK AGENT 95—115 {9. Remove in the order indicated in the table. (Refer to FRONT DIFFERENTIAL.) 3. 27—39} 63—93 {6. MODEL . DRIVE SHAFT REMOVAL/ INSTALLATION. Remove the propeller shaft. ft·lbf} 1 Drive shaft + DRIVE SHAFT.INDEX FRONT DIFFERENTIAL FRONT DIFFERENTIAL REMOVAL/INSTALLATION 1.5—11. Drain the differential oil.7—5.2.8. (Refer to section L. 4. FRONT PROPELLER SHAFT (44). 41—59} N·m {kgf·m. 47—68} 55—80 {5.5.5.TO.INDEX RANG. FROM. FRONT DIFFERENTIAL OIL REPLACEMENT.4—9.BACK.CHAPTER.REPAIR MANUAL PAGES.6—8. MANUAL TO.) 2. Drive Shaft Removal Note 2 3 Front differential component + Removal Note Differential bracket CONTINUED M–46 . Install in the reverse order of removal. 69—85} 37—53 {3.DRFT. FRONT PROPELLER SHAFT REMOVAL/INSTALLATION.

Joint Shaft Component Removal Note 1.BACK. crossmember Front differential 2 3 Front Differential. CONTINUED M–47 . joint shaft component + Removal Note Joint shaft.INDEX FRONT DIFFERENTIAL RFW APPLY LOCKING COMPOUND 94.4—9.7.5—11.2—115.7} 37—53 {3. 68.7 {9.1 {6.DRFT. Remove the front differential and joint shaft component from the vehicle using the transmission jack. MANUAL TO. DRIVE SHAFT REMOVAL/ INSTALLATION. Remove the bolts and nuts indicated by arrows.3} 28—30 {2.TO.8—85.5. Drive Shaft Removal Note Vacuum hose RFW switch component 4 5 6 Front differential.8—3.CHAPTER.5. MODEL .INDEX RANG. ft·lbf} 1 Drive shaft + DRIVE SHAFT. Set the transmission jack on the differential.2—115. 3.8—85. 21—22} 23—26 {2.7—5. 17—19} 94. 68.8—93.1.3—2.REPAIR MANUAL PAGES.7 {9.3} 62. 46.8. FROM. 2.5—11.8.3—68. 27—39} APPLY SCREW LOCK AGENT N·m {kgf·m.

FROM. MODEL .REPAIR MANUAL PAGES. SST À Å Ä É SST È Ã SST SST Ç Æ SST Â Á 1 2 3 4 5 6 Bolt SST 7 8 9 10 11 Adjusting screw Side bearing outer race Locknut + Disassembly Note Washer Companion flange + Disassembly Note Differential casing Oil baffle Differential component + Disassembly Note Lock plate Bearing cap + Disassembly Note CONTINUED M–48 .CHAPTER.TO.DRFT. MANUAL TO.BACK.INDEX FRONT DIFFERENTIAL FRONT DIFFERENTIAL DISASSEMBLY D Disassemble in the order indicated in the table.INDEX RANG.

INDEX FRONT DIFFERENTIAL Locknut Disassembly Note D Hold the companion flange using the SST and remove the locknut.CHAPTER.REPAIR MANUAL PAGES. Differential Component Disassembly Note D Install the differential component on the SSTs.TO. 49 M005 561 49 0107 680A Bearing Cap Disassembly Note D Place a mark on one of the bearing caps so that the left and right bearing caps won’t get mixed up. MARK Drive Pinion Disassembly Note D Remove the drive pinion by tapping with a plastic hammer.BACK.INDEX RANG. 49 0839 425C Oil Seal Disassembly Note D Remove the oil seal using a screw driver. FROM. 49 S120 710 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 Oil seal + Disassembly Note Drive pinion + Disassembly Note Front bearing inner race Collapsible spacer Rear bearing inner race + Disassembly Note Spacer Front bearing outer race + Disassembly Note Rear Bearing outer race + Disassembly Note Carrier Bolt Ring gear Knock pin + Disassembly Note Pinion shaft Pinion gear Thrust washer Side gear Thrust washer Side bearing inner race + Disassembly Note Gear case Companion Frange Disassembly Note D Pull the companion flange out using the SST.DRFT. MANUAL TO. MODEL . CONTINUED M–49 . Use the mark for matching at the time of assembly.

D Remove the bearing outer races using the two 49 0839 425C grooves on the carrier and tapping the outer races alternately.16 in} diameter bar.REPAIR MANUAL PAGES.TO.BACK.CHAPTER. Knock Pin Disassembly Note Caution D Insert the bar from the knock pin hole at the opposite side from where the ring gear is installed. MODEL . D Remove the rear bearing inner race using the SST.INDEX RANG.DRFT. FROM. D Remove the side bearing inner race from the gear case using the SST. Side Bearing Inner Race Disassembly Note 49 H027 002 Caution D Mark the left bearing in order to install in the same position. MANUAL TO. Front Bearing Outer Race. Rear Bearing Outer Race Disassembly Note Note D Mark or otherwise distinguish between the front and rear outer races so that they are not mixed up at the time of reassembly. D Secure the gear case in a vise and remove the knock pin using a 4 mm {0. CONTINUED M–50 .INDEX FRONT DIFFERENTIAL Rear Bearing Inner Race Disassembly Note Note D Mark or otherwise distinguish between the front and rear inner races so that they are not mixed up at the time of reassembly.

184—284 {13—29. MODEL . 28—38} R 18—25 {1.7. 14—18} R SST R SST 69—83 {7.0—8.3. 17—19} R SST 14—51 {3.8—2. 95—209} 23—27 {2. D Install the differential carrier within 10 minutes after applying sealant. D Allow the sealant to set at least 30 minutes after installation before filling the differential with the specified oll.3—2. ft·lbf} 1 2 3 4 5 6 7 8 Gear case + Assembly Note Thrust washer + Assembly Note Side gear Thrust washer Pinion gear Pinion shaft Knock pin Ring gear + Assembly Note 9 10 11 12 13 14 15 Side bearing inner race + Assembly Note Bolt Carrier Front Bearing outer Race + Assembly Note Rear bearing outer race + Assembly Note Spacer + Assembly Note Rear bearing inner race + Assembly Note CONTINUED M–51 .INDEX FRONT DIFFERENTIAL FRONT DIFFERENTIAL ASSEMBLY Caution D Clean away the old sealant before applying the new sealant.CHAPTER.8—5.INDEX RANG.5. MANUAL TO.6.REPAIR MANUAL PAGES.TO. 51—61} R SST R SST SST R SST R SST SST R N·m {kgf·m.DRFT. D Assemble in the order indicated in the table.BACK. FROM.

TO.1 mm {0—0.INDEX FRONT DIFFERENTIAL Standard backlash 0—0.DRFT. Rear Bearing Outer Race Assembly Note D Press the rear bearing outer race into the carrier using the SST and a press. thrust washer.BACK. 49 F027 005 Thrust Washer Assembly Note 1. Set a dial gauge to the pinion gear as shown in the figure. pinion gears. MODEL . FROM. If the backlash exceeds the standard. Secure one of the side gears. 2.REPAIR MANUAL PAGES. D Press the side bearings into the gear case using 16 17 18 19 20 21 22 23 24 25 26 27 28 29 Drive pinion + Assembly Note Collapsible spacer Front bearing inner race Oil seal + Assembly Note Companion flange Washer Locknut + Assembly Note Side bearing outer race + Assembly Note Adjusting screw + Assembly Note Bearing cap + Assembly Note Lock plate Baffle plate Differential casing Bolt the SST. 49 G030 338 Gear Case Assembly Note D Assemble the side gears. Front Bearing Outer Race Assembly Note D Press the front bearing outer race into the carrier using the SST and a press. 49 F027 004 CONTINUED M–52 . 2. make a crimp so that the pin will not come out of the gear case. Install the ring gear and tighten the bolt to the specified torque. Move the pinion gear and measure the backlash at the end of the pinion gear. MANUAL TO.CHAPTER.INDEX RANG. Side Bearing Inner Race Assembly Note Caution D Bearings should be assembled to the original positions. pinion shaft and knock pin.004 in} 4. Ring Gear Assembly Note 1. 3. use the thrust washers to adjust. Coat the ring gear and gear case facing surfaces with locking agent. After assembling the knock pin.

Rear Bearing Inner Race Assembly Note Caution D Press in until the force required suddenly increases. MANUAL TO. Then install this to the carrier. confirm that the installation direction is correct.04 mm. use 0.INDEX FRONT DIFFERENTIAL Spacer Assembly Note Pinion height adjustment Notes D Use the same spacer and nut. and then set the SST (49 0727 570) on top of the SST (49 0350 555). 49 F401 331 49 G030 338 CONTINUED M–53 . D Install the spacer selected for the pinion height adjustment. Place the SST on the surface plate and set the dial indicator to zero. 49 0350 555 49 8531 565 SPACER REAR BEARING 49 8531 568 O RING 49 8531 567 FRONT BEARING 4. washer and nut to the SST (49 8531 565). Place the measuring probe of the dial indicator so that it contacts the place where the side bearing is installed in the carrier. (If there is no figure inscribed.07 mm {0.) This is the pinion height adjustment value. companion flange.TO.07 = adjustment value 2 100 Therefore.BACK. Note D For example. 1. Then measure left and right side of the lower position. From this result. replace it with a spacer 0. subtract the result obtained by dividing the number inscribed on the end surface of the drive pinion by 100. 49 0727 570 49 0350 555 7.CHAPTER. 3. D Press the rear bearing inner race in using the 49 0727 570 SSTs.DRFT. Assemble the spacer. Secure the collar with the O-ring.06 mm and 0. Place the SST (49 0350 555) on top of the SST (49 8531 565). MODEL . D Be careful to install collars A and B in the correct position and facing in the correct direction. 6. Assemble the front bearing inner race. Tighten the nut to the extent that the SST (49 8531 565) can be turned by hand. rear bearing inner race and SST (49 8531 568) on to the SST (49 8531 565). SST (49 8531 567). Add the two (left and right) values obtained by the measurements taken in Step 6 and then divide the total by 2.06+0. SPACER 5.04 – –2 = 0. FROM.REPAIR MANUAL PAGES.003 in} thicker than the currently used one. and the figure inscribed on the end of the drive pinion is –2: pinion height 0. 2.INDEX RANG. the measured results obtained at Step 6 are 0.

49 0259 720 49 U027 003 CONTINUED M–54 . ring gear backlash and the side bearing preload as follows. 95—209 ff·lbf} Drive pinion preload 0. 1.09—0.3 N·m {9—14 kgf·cm. Bearing Cap Assembly Note Ring gear backlash adjustment 1.11 mm {0. (1) Mark the ring gear at four points at approx. MANUAL TO. The torque applied at this time will be used after the oil seal is installed.9—13. collapsible spacer and companion flange to the carrier. Tighten the new locknut using the SST with the determined torque while performing drive pinion preload adjustment. (1) Turn the companion flange by hand to seat the bearing. Preload 0. (2) Use a torque wrench to tighten the locknut temporarily tightened in Step 1.9—12. 2.REPAIR MANUAL PAGES.0035—0. 49 0259 720 (3) If the specified preload can’t be obtained within the specified tightening torque range. Locknut tightening torque 128—284 N·m {13—29 kgf·m. spacer. Assemble the companion flange and washer. while turning the ring gear. 2. MODEL . Verify that the preload is within the specification. front bearing. and temporarily tighten the locknut.BACK.TO. After loosely tightening the bearing outer race and bearing cap mounting bolts. Oil Seal Assembly Note D Apply differential oil to the oil seal lip and press the oil seal in until it touches the end of the differential carrier using the SST.0043 in} using the SST. (4) Remove the locknut.4 N·m {9—14 kgf·cm. 3. 7. washer and companion flange.9—1.1 in·lbf} 49 S120 710 Locknut Assembly Note 1. 7. FROM. completely tighten the adjustment screw by hand. Then.DRFT.INDEX FRONT DIFFERENTIAL Drive Pinion Assembly Note Drive pinion preload adjustment Caution D Do not install the oil seal. Adjust the drive pinion.INDEX RANG. Install the differential gear component to the carrier. (2) Turn both bearing adjusters equally until the backlash becomes 0. Adjusting Screw. alternately tighten the left and right adjustment screws using the SST. 2.9—12. replace the collapsible spacer and inspect again. Install the drive pinion. 90° intervals and mount a dial indicator to the carrier so that the feeler comes in contact at a 90° angle with one of the ring gear teeth.1 in·lbf} 49 S120 710 Side Bearing Outer Race. Adjust the preload of the drive pinon bearing as follows.CHAPTER. and confirm that the specified preload can be obtained within the specified tightening torque range.

(4) If it is not good. Bearing cap bolt tightening torque 38—51 N·m {3.0028 in}.07 mm {0.300—7.50 mm {7. MODEL .CHAPTER. 28—38 ft·lbf} HEEL CONTACT FACE CONTACT Standard distance 185. Toe and flank contact Replace the spacer with a thinner one. adjust the pinion height. The inspection and adjustment procedure is as follows: (1) Coat both surfaces of 6—8 teeth of the ring gear uniformly with a thin red lead coating. then adjust the backlash.REPAIR MANUAL PAGES.303 in} 3.INDEX FRONT DIFFERENTIAL (3) Inspect for the backlash at the three other marked points and make sure that the minimum backlash is more than 0. tighten the adjustment screws equally until the distance between both pilot sections on the bearing caps (L) become as specified. and move the drive pinion outward. wipe off the red lead coating.INDEX RANG. MANUAL TO. rotate the drive pinion several times and inspect the tooth contact.3 kgf·m.002 in} and difference of the maximum and minimum backlash value is less than 0.05 mm {0.43—185. (4) After adjusting the backlash.8—5. TOE CONTACT FLANK CONTACT Heel and face contact Replace the spacer with a thicker one.TO. FROM. Bring the drive pinion inward.BACK. (3) If the tooth contact is good. RED LEAD CONTINUED M–55 . (2) While moving the ring gear back and forth by hand.DRFT.

DRFT. 4 Oil leakage CONTINUED M–56 . or wiring harnesses. Inspect and repair as necessary for trouble caused by other sources. terminals.CHAPTER.REPAIR MANUAL PAGES. D Inspect the connector and terminal connections when inspecting the wiring harnesses. FROM. MANUAL TO. TROUBLESHOOTING PROCEDURE and thoroughly read and understand the basic flow of troubleshooting in order to properly perform the basic procedures.BACK.) Diagnostic Index No 1 TROUBLESHOOTING ITEM No RFW operation from free to lock (RFW indicator light does not illuminate) D D D D D D D D D D D D D D D D D D D D D D D D D D D D D DESCRIPTION Free solenoid valve malfunction RFW indicator light bulb malfunction RFW actuator malfunction RFW switch malfunction Print plate in instrument cluster malfunction METER 15 A fuse malfunction ENGINE 15 A fuse malfunction Transfer neutral switch malfunction 4 4 indicator switch malfunction RFW control module malfunction Lock solenoid valve malfunction RFW control box malfunction Air leakage from vacuum hose One-way check valve malfunction Related fuses and/or harness malfunction Lock solenoid valve malfunction RFW switch malfunction RFW actuator malfunction Print plate in instrument cluster malfunction Engine 15 A fuse malfunction RFW main switch malfunction Transfer neutral switch malfunction 4 4 indicator switch malfunction RFW control module malfunction Free solenoid valve malfunction RFW control box malfunction Air leakage from vacuum hose One-way check valve malfunction Related fuses and/or harness malfunction 2 No RFW operation from lock to free (RFW indicator light does not go off) 3 Noise D Joint shaft bearing abrasion or damage D RFW hub abrasion D Joint shaft abrasion D RFW control box is poorly installed.TO. MODEL .INDEX TROUBLESHOOTING TROUBLESHOOTING REMOTE FREEWHEEL (RFW) Foreword D Refer to section GI. Precaution D This section only mentions unique symptoms of the trouble caused by RFW.INDEX RANG. HOW TO USE THIS MANUAL. (The cause of the malfunction may be a poor connection in the connectors.

INDEX TROUBLESHOOTING Quick Diagnosis Chart Possible factor Troubleshooting item No RFW operation from free to lock No RFW operation from lock to free Noise Oil leakage Ę R R R Pr M EN Tr 4 Ę Ę Ę Ę Ę Ę Ę Ę Ę Ę Ę R R Lo Fr R O Ę Ę Ę Ę Ę Jo R Jo Con Va R Ę Ę Ę Ę Ę Ę Ę Ę Ę Ę Ę Ę Ę Ę Ę Ę Ę Ę Symptom Troubleshooting 1 NO RFW OPERATION FROM FREE TO LOCK (RFW INDICATOR LIGHT DOES NOT ILLUMINATE) RFW does not change from free to lock. Then go to Step 31.REPAIR MANUAL PAGES. Measure voltage between RFW control module connector terminal F and ground. Is the voltage greater than 10 V? Yes No Yes No 4 5 Yes No 6 Measure voltage between RFW control module connector terminal H and ground. Repair wiring harness between instrument cluster and RFW control module. Is the voltage greater than 10 V? Is the METER 15 A fuse okay? Yes No Go to Step 6. Go to next step. Then go to next step. MANUAL TO.DRFT. Replace print plate in instrument cluster.TO. Turn ignition (engine) switch off. MODEL . Is the voltage greater than 10 V? Measure voltage between instrument cluster connector terminal 2H and ground. Go to next step. Then go to Step 31. FROM. Then go to Step 31. Is it okay? Measure voltage between instrument cluster connector terminal 1J and ground. D D D D D D D DESCRIPTION D D D D D D D [TROUBLESHOOTING HINTS] Transfer neutral switch malfunction 4 4 indicator switch malfunction RFW control module malfunction Lock solenoid valve malfunction Free solenoid valve malfunction RFW indicator light bulb malfunction RFW control box malfunction INSPECTION Disconnect RFW control module connector. Replace 15 A METER fuse. Replace RFW indicator light bulb.BACK. Then go to Step 31. Go to next step. 1 METER 15 A fuse and/of ENGINE 15 A fuse malfunction Print plate in instrument cluster malfunction RFW switch malfunction RFW actuator malfunction Air leakage from vacuum hose One-way check valve malfunction Related fuses and/or harnesses malfunction ACTION STEP 2 Yes No 3 Inspect RFW indicator light bulb. Turn ignition (engine) switch off. Go to Step 8. Then go to Step 31. Turn ignition (engine) g ( g ) switch on.CHAPTER. Repair wiring harness between METER 15 A fuse and instrument cluster.INDEX RANG. Then go to next step. Is the voltage greater than 10 V? Yes No CONTINUED M–57 .

Then go to Step 31. Connect lock solenoid valve. Is the voltage greater than 10 V? Measure voltage between RFW control module connector terminal A and ground. Then go to Step 31. Then go to Step 31. 4 indicator No 8 Disconnect free solenoid valve connector. Is the voltage greater than 10 V? Turn ignition (engine) switch off. Is there continuity between RFW control module connector terminal B and ground? Shift select lever to N position. Then go to Step 31. Go to Step 23. Is the voltage greater than 10 V? Measure voltage between RFW control module connector terminal C and ground.INDEX RANG. Then go to Step 31. MANUAL TO. Repair wiring harness between RFW control module and transfer neutral switch. Go to next step. Then go to Step 31. Go to next step. Repair wiring harness between RFW control module and ground. Go to next step. Inspect lock solenoid valve. Repair wiring harness between free solenoid valve and RFW control module. Go to next step. Go to next step. Inspect free solenoid valve. Replace transfer neutral switch. Measure voltage between free solenoid valve connector terminal A and ground. Go to next step. Go to next step.DRFT. Connect free solenoid valve. Repair wiring harness between ENG 15 A fuse and RFW control module. Then go to Step 31. Then go to next step. Then go to Step 31. Then go to Step 31. Repair wiring harness between ENG 15 A fuse and RFW control module. Go to next step. FROM. Repair wiring harness between lock solenoid valve and RFW control module.TO. Repair wiring harness between 4 switch and RFW control module. Go to next step.REPAIR MANUAL PAGES.INDEX TROUBLESHOOTING STEP 7 INSPECTION Is the ENG 15 A fuse okay? Yes ACTION Repair wiring harness between ENG 15 A fuse and RFW control module. MODEL . Then go to Step 31. Then go to Step 31. Is there continuity between RFW control module connector terminal L and ground? Is there continuity between transfer neutral switch connector terminal A and ground? Yes No 9 Yes No Yes No 10 11 Yes No 12 Yes No Yes No 13 14 Yes No 15 Yes No Yes 16 No 17 Inspect transfer neutral switch. Repair wiring harness between transfer neutral switch and ground. Measure voltage between lock solenoid valve connector terminal A and ground. Is there continuity between RFW control module connector terminal K and ground? Is there continuity between 4 4 indicator switch connector terminal A and ground? Yes No Yes 20 No CONTINUED M–58 . Go to next step. Is the voltage greater than 10 V? Measure voltage between free solenoid valve connector terminal B and ground. Go to Step 19. Then go to Step 31. Go to next step. Then go to next step. Then go to Step 31. Is it okay? Is there continuity between transfer neutral switch connector terminal B and ground? Yes No Yes No 18 19 Shift select lever to 4 4 indicator position. Replace the ENG 15 A fuse.CHAPTER.BACK. Is the voltage greater than 10 V? Disconnect lock solenoid valve connector. Is the voltage greater than 10 V? Measure voltage between lock solenoid valve connector terminal B and ground.

Is it okay? Inspect RFW control module. Then go to Step 31. ENGINE 15 A fuse malfunction RFW main switch malfunction RFW actuator malfunction RFW switch malfunction Air leakage from vacuum reservoir or actuator system One-way check valve Print plate in instrument cluster malfunction Related fuses and/or harnesses malfunction ACTION STEP 1 CONTINUED M–59 . Is it okay? Is there continuity between 4 4 indicator switch connector terminal B and ground? Yes No Yes No Go to next step. Then go to Step 31. 4 indicator 22 23 Shift select lever to 4H position. Go to next step. Repair wiring harness between RFW switch and ground. Explain repairs to customer. Then go to Step 31. Then go to Step 31. Replace RFW switch. Then go to Step 31. Is it okay? Is there continuity between RFW switch connector terminal B and ground? Yes No Yes No 26 27 Inspect one-way check valve. Repair or replace RFW control module. Is it okay? Turn ignition (engine) switch on. Troubleshooting completed. Shift select lever from 2H to 4H position. then repeat from Step 1 if malfunction occurs again. Then go to next step.CHAPTER. Repair wiring harness between RFW control module and RFW switch. Does RFW operate from free to lock? Yes No Yes No Yes No Yes No Yes No 28 29 30 31 2 NO RFW OPERATION FROM LOCK TO FREE (RFW INDICATOR LIGHT DOES NOT GO OFF) RFW does not change from lock to free. Go to Step 3.DRFT. Is there continuity between RFW control module connector terminal J and ground? Is there continuity between RFW switch connector terminal A and ground? Yes No Yes 24 No 25 Inspect RFW switch. Go to Step 27 Go to next step. FROM. Go to next step. MODEL .INDEX TROUBLESHOOTING STEP 21 INSPECTION Inspect 4 4 indicator switch. D D D D D D D D DESCRIPTION D D D D D D D [TROUBLESHOOTING HINTS] RFW main switch malfunction Transfer neutral switch malfunction 4 4 indicator switch malfunction RFW control module malfunction Free solenoid valve malfunction Lock solenoid valve malfunction RFW control box malfunction INSPECTION Disconnect RFW control module connector. Replace RFW control box. Then go to Step 31. Replace one-way check valve. Go to next step. Then go to Step 31. Repair vacuum in vacuum hoses. Go to next step.INDEX RANG. MANUAL TO. Then go to Step 31. Go to next step. Is there continuity between RFW control module connector terminal F and ground? Yes No Go to next step.BACK. Go to next step. Repair wiring harness between 4 switch and ground. Inspect malfunction symptoms again. Is it okay? Inspect RFW control box. Is it okay? Inspect vacuum in vacuum hoses. Go to next step.REPAIR MANUAL PAGES. ACTION Replace 4 4 indicator switch. Go to next step.TO.

Is there continuity between RFW control module connector terminal B and ground? Shift select lever to N position. MANUAL TO. Inspect lock solenoid valve. Then go to Step 32. Go to next step. Is the voltage greater than 10 V? Measure voltage between lock solenoid valve connector terminal B and ground. Go to Step 16. Repair wiring harness between RFW control module and transfer neutral switch. Turn ignition (engine) switch on on. Is the voltage greater than 10 V? Measure voltage between RFW control module connector terminal A and ground.BACK. Then go to Step 32. Then go to Step 32. Measure voltage between RFW control module connector terminal H and ground.REPAIR MANUAL PAGES. Then go to Step 32. Inspect for no continuity between Instrument cluster terminal 2H and ground. Then go to Step 32.INDEX TROUBLESHOOTING STEP 2 INSPECTION Disconnect instrument cluster connector No. FROM.TO. Repair wiring harness between free solenoid valve and RFW control module. Replace the ENG 15 A fuse. Measure voltage between lock solenoid valve connector terminal A and ground. Repair wiring harness between ENG 15 A fuse and RFW control module. Then go to next step. Then go to Step 32. Is there continuity between instrument cluster terminal 2H and ground? Yes ACTION Repair wiring harness between RFW control module and instrument cluster. Measure voltage between free solenoid valve connector terminal A and ground. Repair wiring harness between lock solenoid valve and RFW control module. Go to next step. Then go to Step 32. Repair wiring harness between RFW control module and ground.DRFT. Repair wiring harness between ENG 15 A fuse and RFW control module. Go next step. Go to next step. Connect lock solenoid valve.INDEX RANG. Turn ignition (engine) switch off. Is the voltage greater than 10 V? Is the ENG 15 A fuse okay? Yes No 4 Yes No 5 Disconnect free solenoid valve connector. Then go to Step 32. Then go to Step 32. MODEL . Then go to Step 32. Is the voltage greater than 10 V? Turn ignition (engine) switch off. Go next step. Inspect free solenoid valve. Then go to Step 32. Then go to Step 32. Then go to next step. Then go to next step. Replace transfer neutral switch. Repair wiring harness between ENG 15 A fuse and RFW control module. Is there continuity between RFW control module connector terminal L and ground? Is there continuity between transfer neutral switch connector terminal A and ground? Yes No 6 Yes No Yes No 7 8 Yes No 9 Yes No Yes No 10 11 Yes No 12 Yes No Yes 13 No 14 Inspect transfer neutral switch. Go to next step. Go to Step 5. Is the voltage greater than 10 V? Measure voltage between free solenoid valve connector terminal B and ground. Go to next step.2. Is it okay? Yes No CONTINUED M–60 . Is the voltage greater than 10 V? Measure voltage between RFW control module connector terminal C and ground. Is the voltage greater than 10 V? Disconnect lock solenoid valve connector. No 3 Turn ignition (engine) switch off. Connect free solenoid valve. Disconnect RFW control module connector.CHAPTER. Go to next step.

Then go to Step 32. Repair wiring harness between 4 and ground. Then go to Step 32. Repair wiring harness between RFW main switch and RFW control module.CHAPTER. Go to next step.BACK. Then go to Step 32. Then go to Step 32. Is there continuity between RFW main switch connector terminal I and ground? Is there continuity between RFW main switch connector terminal F and ground? Yes No Yes 25 No 26 27 Inspect RFW main switch. Go to next step.DRFT. Go to next step.REPAIR MANUAL PAGES. Replace 4 4 indicator switch. Go to next step.INDEX TROUBLESHOOTING STEP 15 INSPECTION Is there continuity between transfer neutral switch connector terminal B and ground? Yes No Go to next step. Go to next step. Then go to Step 32. Then go to Step 32. Go to Step 28. Go to Step 28. 4 indicator switch 16 Shift select lever to 2H position. Replace RFW switch. Is it okay? Inspect RFW actuator. Repair wiring harness between RFW control module and 4 4 indicator switch. Replace RFW main switch. Go to next step. ACTION Repair wiring harness between transfer neutral switch and ground. Go to next step. Is it okay? Yes No Yes No Yes No 29 30 CONTINUED M–61 . Then go to Step 32. Then go to Step 32. Go to Step 20. FROM. Repair wiring harness between RFW switch and ground.INDEX RANG. MANUAL TO. Then go to Step 32. Is it okay? Inspect vacuum in vacuum hoses. Then go to Step 32. Repair wiring harness between RFW switch. Go to next step. Go to next step. Is it okay? Is there continuity between 4 4 indicator switch connector terminal B and ground? Yes No Yes No 19 20 Shift select lever to 4H position. Is there continuity between RFW control module connector terminal J and ground? Is there continuity between RFW switch connector terminal A and ground? Inspect RFW switch. Go to next step. Then go to Step 32. Is there continuity between RFW control module connector terminal K and ground? Is there continuity between 4 4 indicator switch connector terminal A and ground? Yes No Yes 17 No 18 Inspect 4 4 indicator switch. Go to next step.TO. Is it okay? Is there continuity between RFW main switch connector terminal D and ground? Yes No Yes No 28 Inspect one-way check valve. Go to next step. Go to next step. Replace one-way check valve. Go to next step. Repair vacuum in vacuum hoses. MODEL . Repair wiring harness between RFW main switch and ground. Is it okay? Is there continuity between RFW switch connector terminal B and ground? Yes No Yes No 21 22 Yes No Yes No 23 24 Push RFW main switch on. Replace RFW actuator. Go to next step. Then go to Step 32.

Inspect malfunction symptoms again. Inspect conventional front differential parts. Troubleshooting completed. 2 Malfunction is caused by something other than RFW. ACTION Repair or replace RFW control module.CHAPTER.REPAIR MANUAL PAGES. Replace joint shaft. MANUAL TO. Inspect malfunction symptoms again. Go to next step. Troubleshooting completed. Go to next step. then repeat from Step 1 if malfunction occurs again. Is it okay? Malfunction is caused by other than RFW. 5 4 OIL LEAKAGE The oil leaks from front differential. ACTION Replace joint shaft bearing.INDEX TROUBLESHOOTING STEP 31 INSPECTION Inspect RFW control module. Explain repairs to customer. Go to next step. then repeat from Step 1 if malfunction still occurs. Replace defective part(s). Then go to next step. FROM. Does RFW operate from free to lock? Yes No Yes No Go to next step. Replace defective part(s).DRFT. Replace RFW hub.INDEX RANG. 32 3 NOISE Noise is heard from front differential. Then go to Step 3. Is it okay? Inspect RFW hub. Is it okay? Inspect joint shaft. Move selector lever from 2H to 4H position. Troubleshooting completed. then repeat from Step 1 if malfunction occurs again. D Joint shaft abrasion D Conventional front differential parts malfunction DESCRIPTION [TROUBLESHOOTING HINTS] D Joint shaft bearing abrasion or damage D RFW hub abrasion STEP 1 2 3 4 INSPECTION Inspect joint shaft bearing.TO. Explain repairs to customer. Is it okay? Turn ignition (engine) switch on. D Malfunction of conventional front differential parts DESCRIPTION [TROUBLESHOOTING HINTS] D Poor installation of the RFW control box STEP 1 INSPECTION Is RFW control box installed completely? Yes No Go to next step. Go to next step. parts Are they okay? Has front differential noise stopped? Yes No Yes No Yes No Yes No Yes No Go to next step. Inspect conventional front differential parts. Explain repairs to customer. MODEL .BACK. Are they okay? Is there any oil leakage from front differential? Yes No Yes No 3 CONTINUED M–62 . Inspect malfunction symptoms again. ACTION Install RFW control box securely.

. . . . N–4 STEERING GEAR AND LINKAGE REMOVAL/INSTALLATION . N–12 STEERING GEAR AND LINKAGE REMOVAL/INSTALLATION . either the steering When a wheel is removed. . . . . . . . . . . N–14/15 STEERING GEAR AND LINKAGE INSPECTION . .18 in} the fluid lines. .SUSPENSION. . . . . . . . . . . . FROM. . N–12 STEERING SHAFT INSPECTION . . . . . N–10/12 STEERING WHEEL AND COLUMN INSPECTION . . and inspect for leakage after the procedure has been completed. add Steering wheel play ATF M–III or equivalent (e. . . . . . . . . . . N–1 MANUAL STEERING . N–10 POWER STEERING FLUID INSPECTION . . . . . . . . . . . . Wheels and Tires. . N–1 STEERING WHEEL AND COLUMN INSPECTION . . . . . With the wheels in the straight-ahead (Refer to section TD. . . . . . N–12 STEERING WHEEL AND COLUMN REMOVAL/INSTALLATION . N–1/2 STEERING WHEEL AND COLUMN REMOVAL/INSTALLATION . . . . . . . . . N–21 GENERAL PROCEDURES MANUAL STEERING Wheels and tires removal/installation STEERING WHEEL AND COLUMN INSPECTION D The removal and installation procedures for the Steering Wheel Play Inspection wheels and tires are not mentioned in this section. . is excessive. . . . . . . . . Reconnect the negative battery cable only after the work is completed. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MODEL . . . . .) position. . . CONTINUED N–1 .INDEX STEERING SYSTEM GENERAL PROCEDURES . . N–19/20 POWER STEERING OIL PUMP (WL. . . . . . . . . . . . . .TO. D If the play exceeds specification. . . . . . . . . . . . . . . . N–10 AIR BLEEDING . . . . . . .DRFT. . . N–7/9 STEERING GEAR AND LINKAGE INSPECTION . . . . . . . . . . .MAIN. . . . . . . . . . . . . . . . Steering Wheel Looseness Inspection D Move the steering wheel as shown in the figure to Connectors disconnection/connection inspect for column bearing wear. . . . . . . N–5/6 STEERING GEAR AND LINKAGE DISASSEMBLY/ASSEMBLY . . . . . retighten it to the joints are worn or the backlash of the steering gear specified torque. . . . . . . . . Dexron® II). . . . . . . . . . . . . . . . . . . . . . . .INDEX RANG. . . . WL TURBO) DISASSEMBLY/ASSEMBLY . . . . . . . . . . .BACK. . . . . . N–15 POWER STEERING OIL PUMP REMOVAL/INSTALLATION . steering shaft D Disconnect the negative battery cable before doing joint play. . . . and column any work that requires handling of connectors. . . . . . . . . . . . . . . . . . . . . . . . . looseness. . . . . . . . . . . . . N–13 STEERING GEAR AND LINKAGE DISASSEMBLY/ASSEMBLY .g. . . . . . . . . . . . . . . N–3/4 STEERING SHAFT INSPECTION . . . . . .REPAIR MANUAL PAGES. . . . . D If any power steering fluid line has been disconnected anytime during the procedure. . . . N–9 POWER STEERING . . F2 CARB. . . . . . . . . . . gently turn the steering wheel to the left and right and verify that the play is within Power steering components removal/installation specification. . bleed 0—30 mm {0—1. . . . . steering wheel looseness. . . . . MANUAL TO. . N–16/18 POWER STEERING OIL PUMP (F2 CIS. . . . . . . G6) DISASSEMBLY/ASSEMBLY . . . .

AIR BAG SYSTEM. With the vehicle on a hard. FROM. and steering joints. level surface.BACK.REPAIR MANUAL PAGES. put the wheels in the straight-ahead position. if equipped. 4.INDEX MANUAL STEERING Steering Wheel Effort Inspection 1.INDEX RANG.5 N·m {460 kgf·cm. MANUAL TO. (Refer to section T. Steering wheel effort 4. 2.TO. rotation torque of each ball joint. 399 in·lbf} max. DRIVER-SIDE AIR BAG MODULE REMOVAL/INSTALLATION.) 3. Remove the air bag module. MODEL .CHAPTER.DRFT. Measure the steering wheel effort using a torque wrench. If not as specified. CONTINUED N–2 . inspect the following: rotation starting torque of pinion.

0—5.3. 29—36} AIR BAG MODEL R 16—22 {1. MANUAL TO. 14—18} 20—26 {2. FROM.CHAPTER. 2.7. 12—16} 20—26 {2.0—2. MODEL .0.DRFT.REPAIR MANUAL PAGES. 29—36} 40—50 {4.3.6—2.INDEX RANG. Install in the reverse order of removal.TO. ft·lbf} 1 2 Horn cap Air bag module (with air bag) + section T.8—2. DRIVER-SIDE AIR BAG MODULE REMOVAL/INSTALLATION Locknut Steering wheel + Removal Note + Installation Note Column cover 6 7 8 9 10 11 Combination switch Steering shaft + Installation Note Universal joint Boot Intermediate shaft Steering lock component + Removal Note + Installation Note 3 4 5 CONTINUED N–3 . Remove in the order indicated in the table. 12—16} 16—22 {1.7. AIR BAG SYSTEM. 15—19} 18—24 {1. 40—50 {4.5.BACK.INDEX MANUAL STEERING STEERING WHEEL AND COLUMN REMOVAL/INSTALLATION 1.0—2. 15—19} N·m {kgf·m.0.0—5.6—2.

27 in} Steering Shaft Installation Note 1. 2. Steering Lock Component Removal Note D Use a chisel to make a groove in the heads of the steering lock mounting bolts. 3.17—32. Tighten the bolts until the heads break off. The column will collapse. Needle and ball bearing damage. D Set the wheels in the straight-ahead position.BACK. MODEL .CHAPTER. CLOCK SPRING ADJUSTMENT. Tighten the bolt A to the specified torque. adjust the clock spring. 2.6—2. 1. Steering shaft length.TO.) 2. MANUAL TO. Tightening torque 16—22 N·m {1.9 mm {32.3 kgf·m. A B Steering Lock Component Installation Note D Install the new steering lock mounting bolts. Remove the bolts using a screwdriver.9—819. CLOCK SPRING. STEERING SHAFT INSPECTION D Inspect the following. CONTINUED N–4 . For vehicles with air bags. Steering Wheel Installation Note 1. Tighten the nut B to the specified torque. and replace the column component as necessary. Length 816. Remove the steering lock component.DRFT. FROM. 12—16 ft·lbf} 3. (Refer to section T. remove the steering wheel using a suitable puller.INDEX MANUAL STEERING Steering Wheel Removal Note Caution D Do not try to remove the steering wheel by hitting the shaft with a hammer.INDEX RANG.REPAIR MANUAL PAGES. Install the steering wheel with the vehicle in the straight-ahead position. Temporarily tighten the bolt A. Dust boot damage.

INDEX MANUAL STEERING STEERING GEAR AND LINKAGE REMOVAL/INSTALLATION 1.5. ft·lbf} 1 2 3 4 5 6 7 8 Cotter pin Nut Ball joint + Removal Note Locknut Tie rod Center link Idler arm + Removal Note Bushing 9 10 11 12 13 14 15 Washer Bolt.5—6. nut.0. 58—115} SST 69—78 {7.0.CHAPTER. MANUAL TO.0—2.BACK.0—8. 51—57} R SST R R R SST 45—58 {4.7—5.0—16. With the wheels in the straight-ahead position.DRFT. washer Bolt Steering gear and pitman arm + Removal Note Dust boot + Removal Note + Installation Note CONTINUED N–5 . 2. MODEL .7—5.5. 33—43} 45—58 {4. FROM. Install in the reverse order of removal.7.0. 33—43} 79—157 {8. 15—19} 45—58 {4.5—6.TO. nut. 33—43} 37—54 {3.5—6. washer Idler arm bracket Bolt.5—6. remove in the order indicated in the table. 37—54 {3.0.0.0.INDEX RANG. 27—39} 20—26 {2. 27—39} 45—58 {4. 33—43} R SST SST N·m {kgf·m.REPAIR MANUAL PAGES.

Put a small amount of lithium-based grease into a new dust boot. Steering Gear and Pitman Arm Removal Note D Remove the ball joint from the knuckle and center link. Install the dust boot using the SST and a press.INDEX MANUAL STEERING Ball Joint. Remove the dust boot by tapping it with a hammer.BACK. 49 T028 3A0 Dust Boot Removal Note 1. FROM. Place the chisel against the boot and hold it at the angle shown.TO. the idler arm from the center link. and steering gear and pitman arm from the center link using the SST. 49 1243 785A CONTINUED N–6 . 3. 2. Idler Arm. 2.REPAIR MANUAL PAGES. MODEL . MANUAL TO. Dust Boot Installion Note 1.CHAPTER. Wipe the grease off the ball joint.DRFT.INDEX RANG.

11—15} 15—24 {1. Assemble in the reverse order of disassembly.INDEX MANUAL STEERING STEERING GEAR AND LINKAGE DISASSEMBLY/ASSEMBLY 1.2. 95—122} R SST R R R 197—235 {20. 25—34} 15—21 {1. 11—18} R 128—166 {13.TO. MODEL . MANUAL TO.5—2.0.5—3.REPAIR MANUAL PAGES.0—17. ft·lbf} 1 2 3 4 5 6 Nut Pitman arm + Disassembly Note Clip Dust boot + Assembly Note Locknut (side cover) + Disassembly Note Sector shaft + Disassembly Note + Assembly Note Side cover Adjusting shim 9 10 11 12 13 14 15 16 17 Adjusting screw Oil seal Retaining ring Locknut + Disassembly Note Oil seal Adjusting nut + Disassembly Note Bearing Worm ball nut + Assembly Note Bearing 7 8 CONTINUED N–7 .0—24.INDEX RANG. FROM.5—2.CHAPTER. 145—173} SST R N·m {kgf·m. Disassemble in the order indicated in the table. 25—34 {2. 2.5.0.DRFT.BACK.5.

Loosen the locknut.INDEX MANUAL STEERING Pitman Arm Disassembly Note D Separate the pitman arm from the steering gear using the SST. Adjusting Nut Disassembly Note D Remove the adjusting nut using the SST.REPAIR MANUAL PAGES.BACK. FROM. adjust the preload. Set the sector shaft in the middle position. 49 0180 510B Worm ball nut preload 1.CHAPTER. (1) Loosen the locknut and turn the adjusting screw using the SST. MANUAL TO. Inspect the worm ball nut preload using the SST. Worm Ball Nut Assembly Note 1.INDEX RANG. 49 UB39 585A 49 U032 3A0 Locknut (Side Cover).7—12. 4.1 in·lbf} [Without the sector shaft] 2.TO. Locknut Disassembly Note D Remove the locknut using the SST.0—1. Remove the side cover attaching bolts. Sector Shaft Disassembly Note 1.3 N·m {10—14 kgf·cm. 49 U032 201 49 U032 201 CONTINUED N–8 . 5. 3. MODEL . If not as specified.DRFT. Tap the sector shaft lower end using a plastic hammer to loosen the sector shaft. 8. Lift and remove the sector shaft with the locknut and the side cover from the gear housing. 2.

Adjust the clearance to the specified value if the clearance is more than the specified value.INDEX MANUAL STEERING (2) Tighten the locknut to the specified torque using the SST. 95—122 ft·lbf} 49 U032 201 49 U034 209 5.004 in) Adjusting shim thickness 1. Wipe the grease off the ball joint. 3. STEERING GEAR AND LINKAGE INSPECTION Steering Gear Backlash Adjustment (3) Inspect the worm ball nut preload again. MANUAL TO.CHAPTER.00 mm {0. D Turn the adjusting screw to adjust steering gear backlash. Set the adjusting screw and shim.BACK. Caution D Adjust the backlash while keeping the steering gear in the center position. 4.03 mm {0.REPAIR MANUAL PAGES. in the “T” groove.079 in} 2.INDEX RANG.077 in} 2. Sector Shaft Assembly Note 1. Clearance 0—0. the backlash becomes excessively small and gears may be damaged. 2.06 mm {0. Dust Boot Assembly Note 1.TO. Measure the clearance in the axial direction. Install the dust boot onto the ball joint. CONTINUED N–9 . 4. 2.079 in} 2.081 in} 2. MODEL .DRFT.97 mm {0. Assemble the sector shaft in such a way that the teeth of the sector shaft mesh with the center part of the teeth of the worm ball nut.1 mm (0—0. Set the SST over the boot and install a new clip.09 mm {0. Put a small amount of lithium-based grease into a new dust boot. Wipe away excessive grease.082 in} Caution D Be careful not to damage the oil seal and bearing. Backlash 0 mm ADJUSTING SHIM 3. Otherwise. Tightening torque 128—166 N·m {13—17 kgf·m. FROM.

) 2. Fluid Level Inspection. MODEL . 5. 2. Add fluid as necessary and repeat Steps 8 and 9. Verify that the fluid is not foamy and that the fluid level has not dropped.H.D. Note D The points where fluid leakage may occur are indicated in the figure. Turn the steering wheel fully to the left and right several times with the engine not running. R. do not keep the steering wheel in the fully turned position for more than 5 seconds. Add fluid to the specified level as necessary. Start the engine and let it idle.CHAPTER.g. add fluid. MANUAL TO. Reinspect the fluid level.H. Turn the steering wheel fully to the left and right to apply fluid pressure. POWER STEERING FLUID INSPECTION Fluid Level Inspection D Inspect the power steering fluid level. 8. Dexron® II) Fluid Leakage Inspection Caution D To prevent damage to the steering system.D. 1. F2 CIS F2 CARB F2 CIS F2 CARB WL WL TURBO WL WL TURBO G6 G6 CONTINUED N–10 . Start the engine and let it idle.INDEX RANG.REPAIR MANUAL PAGES. Inspect for fluid leakage. 3. Turn the steering wheel fully to the left and right several times. 10.BACK. POWER STEERING FLUID INSPECTION. 6.INDEX POWER STEERING POWER STEERING AIR BLEEDING 1.TO. If it has dropped. Inspect the fluid level. L. Fluid specification ATF M–III or equivalent (e. (Refer to POWER STEERING. Jack up the front of the vehicle and support it on safety stands.DRFT. 7. Repeat Steps 3 and 4 until the fluid level stabilizes. FROM. 9. 4. Lower the vehicle.

Tightening torque 30—44 N·m {3. replace the oil pump component.000—1. 24—34 ft·lbf} F2 CIS. MODEL . Turn the steering wheel fully to left and right and measure the fluid pressure generated at the gear housing. F2 CARB. 1280—1350 psi} 49 B032 304 F2 CIS. the fluid temperature will increase excessively and adversely affect the oil pump.5 kgf·m. G6 Caution D If the steering wheel is kept in the fully turned position for more than 5 seconds.REPAIR MANUAL PAGES. Install and tighten the pressure pipe to the specified torque. the fluid temperature will rise excessively and adversely affect the oil pump.0—4.3 MPa {90—95 kgf/cm2.INDEX RANG. CONTINUED N–11 . Attach the SST (49 G032 304). Open the gauge valve fully. Start the engine and turn the steering wheel fully left and right to raise the fluid temperature to 50—60 °C {122—140 °F}. Gear housing fluid pressure 8. Increase the engine speed to 1.500 rpm. Remove the SSTs. 1280—1350 psi} 49 H002 671 THERMOMETER 50—60 °C {122—140 °F} GAUGE CLOSE VALVE COMPLETELY 2.BACK. If the pressure is not within the specification. FROM. Connect the SSTs (49 1232 670A and 49 H002 671) to the SST (49 G032 304).9—9. Bleed the air from the system.0—4.DRFT. 22—32 ft·lbf} 4. 9.5 kgf·m. 6. Disconnect the pressure hose from the oil pump.TO. If the pressure is not within the specification.2—4. WL Turbo: 30—44 N·m {3. MANUAL TO. Bleed the air from the system. Mark both hose connections to ensure that the hose is reinstalled in its original position. Caution D If the valve is left closed for more than 5 seconds. repair or replace the steering gear component.000—1.INDEX POWER STEERING Fluid Pressure Inspection 1. 22—32 ft·lbf} 11.9—9.8 kgf·m. Tightening torque G6: 32—47 N·m {3. WL. Open the gauge valve fully and increase the engine speed to 1. 3. Close the gauge valve completely. 8. F2 CARB. Assemble the SSTs as shown in the figure. 10. WL TURBO 49 G032 3A4 THERMOMETER 50—60 °C {122—140 °F} GAUGE OPEN VALVE COMPLETELY 49 H002 671 5.CHAPTER. WL.500 rpm and measure the fluid pressure generated by the oil pump.3 MPa {90—95 kgf/cm2. 49 1232 670A 7. Oil pump fluid pressure 8.

and compare the results. DRIVER-SIDE AIR BAG MODULE REMOVAL/INSTALLATION.) STEERING SHAFT INSPECTION (Refer to MANUAL STEERING. wear. Road conditions. perform the inspection on another vehicle of the same model and under the same conditions. Inspect the following points: D Tire size and tire pressure D Fluid level 2. (Refer to section T.) Steering Wheel Effort Inspection 1. STEERING WHEEL AND COLUMN REMOVAL/INSTALLATION. CONTINUED N–12 . Start the engine and warm the power steering fluid to 50—60 °C {122—140 °F}.CHAPTER. D The steering wheel effort varies with conditions as shown below. 3.BACK. STEERING SHAFT INSPECTION. Tire conditions.) STEERING WHEEL AND COLUMN INSPECTION Steering Wheel Play Inspection (Refer to MANUAL STEERING. With the vehicle on a hard. if equipped. MODEL .TO. AIR BAG SYSTEM. Measure the steering wheel effort using a torque wrench. such as brand. inspect the following points: D Air in system D Fluid leakage at hose or connectors D Function of oil pump and steering gear STEERING WHEEL AND COLUMN REMOVAL/INSTALLATION (Refer to MANUAL STEERING. If not as specified. STEERING WHEEL AND COLUMN INSPECTION.REPAIR MANUAL PAGES. such as dry or wet. 69 in·lbf} max.DRFT. 4. and tire pressure. level surface.INDEX POWER STEERING Note D To determine whether the steering effort is satisfactory or not.8 N·m {80 kgf·cm. MANUAL TO. Remove the air bag module. Steering Wheel Play Inspection.INDEX RANG. Steering Wheel Looseness Inspection. put the wheels in the straight-ahead position. 1. 2.) 5. 12. FROM. Steering wheel effort 7. STEERING WHEEL AND COLUMN INSPECTION. and asphalt or concrete.) Steering Wheel Looseness Inspection (Refer to MANUAL STEERING.

6. 15—19} SST 69—78 {7.7—5.TO.7—5.0. Install in the reverse order of removal. 58—115} R 37—54 {3. washer 11 12 13 14 15 16 Idler arm bracket Pressure pipe Return pipe Bolt Bolt.INDEX RANG. 51—57} SST R 79—157 {7. Remove in the order indicated in the table. 2.BACK. ft·lbf} 1 2 3 Cotter pin Locknut Ball joint + MANUAL STEERING. STEERING GEAR AND LINKAGE REMOVAL/INSTALLATION. MANUAL TO.5—6.5. Idler Arm Removal Note Bushing Washer Bolt.2—4. Dust Boot Disassembly Note + MANUAL STEERING. STEERING GEAR AND LINKAGE REMOVAL/INSTALLATION.INDEX POWER STEERING STEERING GEAR AND LINKAGE REMOVAL/INSTALLATION 1.5—6. 27—39} 20—26 {2. Dust Boot Assembly Note 4 5 6 7 17 8 9 10 CONTINUED N–13 . nut.7. washer Steering gear and pitman arm + MANUAL STEERING. Ball Joint Removal Note Locknut Tie rod Center link Idler arm + MANUAL STEERING.DRFT. MODEL .REPAIR MANUAL PAGES. Steering Gear and Pitman Arm Removal Note Dust boot + MANUAL STEERING. STEERING GEAR AND LINKAGE REMOVAL/INSTALLATION. FROM.0—8. 32—47 {3. nut.0.0—2.4—3.5.0.CHAPTER.0—16. 33—43} R SST R 45—58 {4.8. 24—34} 24—35 {2. 18—26} 37—54 {3. 27—39} 45—58 {4.0. STEERING GEAR AND LINKAGE REMOVAL/INSTALLATION. STEERING GEAR AND LINKAGE REMOVAL/INSTALLATION. 33—43} SST SST N·m {kgf·m.

Dust Boot Assembly Note Locknut + MANUAL STEERING. STEERING GEAR AND LINKAGE DISASSEMBLY/ASSEMBLY.CHAPTER. 42—47} R SST R R R SST 197—235 {20. MODEL .5. STEERING GEAR AND LINKAGE DISASSEMBLY/ASSEMBLY.7—6. Assemble in the reverse order of disassembly. 22—32} R R R R R R R R R 56—63 {5. MANUAL TO. ft·lbf} 1 2 Nut Pitman arm + MANUAL STEERING. 57—64 {5. FROM.0—4. STEERING GEAR AND LINKAGE DISASSEMBLY/ASSEMBLY.TO.INDEX RANG.INDEX POWER STEERING STEERING GEAR AND LINKAGE DISASSEMBLY/ASSEMBLY 1.0.DRFT. Disassemble in the order indicated in the table.5. Locknut (Side Cover). Sector Shaft Disassembly Note Sector shaft + MANUAL STEERING.5. Pitman Arm Disassembly Note Clip Dust boot + MANUAL STEERING.0—24. 145—173} N·m {kgf·m.7—6. Locknut (Side Cover) Sector Shaft Disassembly Note Side cover 8 9 10 11 12 13 14 15 16 17 18 19 20 21 O-ring Y packing Back up ring Oil seal Back up ring Y packing Dust cover Snap ring Washer Oil seal Valve and piston component + Assembly Note O-ring Seal ring Gear housing 3 4 5 6 7 CONTINUED N–14 . 42—47} 30—44 {3. STEERING GEAR AND LINKAGE DISASSEMBLY/ASSEMBLY. 2.REPAIR MANUAL PAGES.BACK.

) CONTINUED N–15 .DRFT. MODEL . Steering Gear Backlash Adjustment.CHAPTER.BACK.INDEX RANG.INDEX POWER STEERING Valve and Piston Component Assembly Note Caution D Do not scratch the seal ring and O-ring on the piston against the entrance to the housing. FROM. STEERING GEAR AND LINKAGE INSPECTION. MANUAL TO.REPAIR MANUAL PAGES. D Insert the valve and piston component to the gear housing. STEERING GEAR AND LINKAGE INSPECTION (Refer to MANUAL STEERING. D Insert the piston by slightly turning to the left and right so as not to create flection at the O-ring and seal ring.TO.

DRIVE BELT.0. MODEL . 22—32} R 30—39 {3. MANUAL TO.INDEX RANG.CHAPTER.DRIVE BELT ADJUSTMENT.5.0—4.BACK.0—4. ft·lbf} CONTINUED N–16 .REPAIR MANUAL PAGES.) F2 CIS. FROM. (Refer to Section B2.TO.DRFT. 37—43} N·m {kgf·m. Install in the reverse order of removal. adjust the drive belt. Remove in the order indicated in the table.0. 3. F2 CARB 30—44 {3. For F2 CIS. 2. 22—28} SST 50—59 {5. F2 Carb and G6 engine model.0—6.INDEX POWER STEERING POWER STEERING OIL PUMP REMOVAL/INSTALLATION 1.

F2 Carb).2—4. 49 G032 354 CONTINUED N–17 .REPAIR MANUAL PAGES. 37—43} SST CLAMP POSITION 30 mm {1.DRFT.9—2.BACK.0—6.INDEX RANG. 14—18} 32—47 {3. pressure hose (G6) 5 6 7 Return hose Power steering fluid pressure switch connector (except F2 Carb) Power steering oil pump component Locknut Removal Note D Secure the pulley using the SST and remove the locknut.8. 24—34} 32—46 {3.7. 24—33} 50—59 {5. MANUAL TO.2 in} N·m {kgf·m.6. MODEL . ft·lbf} 1 2 3 4 Drive belt Locknut + Removal Note Oil pump pulley Pressure pipe (F2 CIS. FROM.TO.0.CHAPTER.2—4.INDEX POWER STEERING G6 19—25 {1.

INDEX POWER STEERING WL.9—2. MODEL .CHAPTER.TO. 22—32} R 19—25 {1.6. ft·lbf} 1 2 3 Pressure pipe Return hose Bolt and nut 4 5 Power steering oil pump O-ring CONTINUED N–18 . WL TURBO 30—44 {3.BACK.REPAIR MANUAL PAGES.0—4.9—2.DRFT.INDEX RANG. MANUAL TO. FROM.6. 14—18} 19—25 {1.5. 14—18} R N·m {kgf·m.

2—2.REPAIR MANUAL PAGES. MANUAL TO.9—13. The following procedure is for replacement of the O-rings only.6—2. MODEL . 11—14} 9.0.0.7 N·m {100—140 kgf·cm. F2 CARB. G6) DISASSEMBLY/ASSEMBLY 1. 12—17} 18—21 {1. Replace the pump component if other repairs are necessary.7 N·m {80—120 kgf·cm.8—2.TO.6. 14—16} 22—25 {2.INDEX POWER STEERING POWER STEERING OIL PUMP (F2 CIS.4.CHAPTER.DRFT.0—7.2. 87—121 in·lbf} G6 7.INDEX RANG. R 15—19 {1. 2. 16—18} À SST N·m {kgf·m. ft·lbf} 1 2 3 4 5 6 7 8 9 10 11 12 Power steering oil pump component + Disassembly Note Pressure switch component O-ring Nut (G6) Connector (G6) Connector bolt O-ring Control valve component Spring Suction pipe O-ring Shaft component 13 14 15 16 17 18 19 20 21 22 Rear body + Assembly Note O-ring Cam ring + Assembly Note Rotor Vane + Assembly Note Pin Side plate + Assembly Note O-ring Oil seal Front body CONTINUED N–19 . 16—18} R R R F2 CIS 50—68 {5. 70—104 in·lbf} R 22—25 {2. FROM.5—2. Disassemble in the order indicated in the table.9—11. Assemble in the reverse order of disassembly.6. 37—50} R R F2 CARB 16—23 {1. 3.BACK.2—2.

DRFT.INDEX RANG.BACK. Install the cam ring with the marks facing the front body. Install the vanes in the rotor with the rounded edges outward. 49 F032 301 ROUND EDGE Rear Body Assembly Note D After installing the rear body.INDEX POWER STEERING Power Steering Oil Pump Disassembly Note Caution D To secure the oil pump in a vise. Install a new O-ring and the side plate to the front body. MODEL .TO. FROM. 2. Position the side plate using the rear body. MARK CONTINUED N–20 .CHAPTER. Side Plate Assembly Note 1. MANUAL TO. Install the rotor with the mark facing the rear body.REPAIR MANUAL PAGES. 3. manually turn the shaft to verify that it rotates smoothly. Vane. 2. Cam Ring Assembly Note 1. use the SST as shown to prevent damage to the pump.

2. The following procedure is for replacement of the O-rings only.1 in·lbf} 22—25 {2. Assemble in the reverse order of disassembly.INDEX POWER STEERING POWER STEERING OIL PUMP (WL.REPAIR MANUAL PAGES. MODEL . WL TURBO) DISASSEMBLY/ASSEMBLY 1.0. Rear Body Assembly Note O-ring 10 Cam ring + POWER STEERING POWER STEERING OIL PUMP (G6) REMOVAL/INSTALLATION. Disassemble in the order indicated in the table. R 7. ft·lbf} 1 Power steering oil pump component + POWER STEERING.DRFT. MANUAL TO.TO.BACK. Power Steering Oil Pump Component Disassembly Note Suction pipe O-ring Connector O-ring Control valve Spring Rear body + POWER STEERING. 69. FROM. Vane Assembly Note Side plate + POWER STEERING.7 N·m {80—120 kgf·cm. Side Plate Assembly Note O-ring Front body 2 3 4 5 6 7 8 11 12 13 14 15 9 CONTINUED N–21 .INDEX RANG.CHAPTER. 37—50} N·m {kgf·m. Cam Ring Assembly Note Rotor Vane + POWERSTEERING.5—104. POWER STEERING OIL PUMP (G6) REMOVAL/INSTALLATION.9—11. POWER STEERING OIL PUMP (G6) REMOVAL/INSTALLATION. 16—18} R SST R R 50—68 {5.6.2—2. POWER STEERING OIL PUMP (G6) REMOVAL/INSTALLATION. Replace the pump component if other repairs are necessary.0—7. 3. POWER STEERING OIL PUMP (G6) REMOVAL/INSTALLATION.

. . . . . . . POWER BRAKE UNIT REMOVAL/ INSTALLATION . . . . . . . . . . . . . . MODEL . . . . . . . . . . . . Reconnect the negative battery cable only after the work is completed. . . . . . . . . . . . . . . . When a wheel is removed. . . . . . . . . . . . . . . . . FRONT BRAKE (DISC) REMOVAL/ INSTALLATION . . . . FROM. . . .INDEX BRAKING SYSTEM GENERAL PROCEDURES . . . . . . . . . . . . . wipe it off immediately. . . . . . CONVENTIONAL BRAKE SYSTEM . . . . . . . . .MAIN. . . . . . . . . . . . . D If any brake line has been disconnected anytime during the procedure. . . P–11 P–12 P–13/14 P–14 P–14 P–15 P–15 P–16 P–16 P–16 P–16 P–16 P–17 P–18/19 GENERAL PROCEDURES Wheel and tires removal/installation D The removal and installation procedures for the wheels and tires are not mentioned in this section. .BACK. . . . . PARKING BRAKE (STICK TYPE) ADJUSTMENT . LOAD SENSING PROPORTIONING VALVE INSPECTION . . . . . . . . . . . . . . . . . . . . . . PARKING BRAKE LEVER (STICK TYPE) REMOVAL/INSTALLATION . . . . . . . . . . retighten it to the specified tightening torque. . . . . . . REAR BRAKE (DRUM) INSPECTION . Be sure to modify the brake pipe flare nut tightening torque to allow for use of a torque wrench-SST combination. If brake fluid get on a painted surface. . . Fluid specification SAE J1703 or FMVSS116 DOT–3 or DOT–4 CONTINUED P–1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .) Connectors disconnection D Disconnect the negative battery cable before doing any work that requires handling of connectors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . VACUUM PUMP REMOVAL/INSTALLATION . BRAKE PEDAL INSPECTION . . . . . VACUUM PUMP INSPECTION . . . . .DRFT. referring to section TD. . . . . . . . . . . . . . . . . . . . . . . . . . FUNDAMENTAL PROCEDURES. . . . . VACUUM SWITCH INSPECTION . . . . . . . . . . . . . . PARKING BRAKE CABLE (STICK TYPE) REMOVAL/INSTALLATION . . . . . . MASTER CYLINDER REMOVAL/ INSTALLATION . . LOAD SENSING PROPORTIONING VALVE REMOVAL/INSTALLATION . . . . . . MASTER CYLINDER DISASSEMBLY/ ASSEMBLY . . . . . . . . . bleed the brakes. . . . . . . . . . . . . . . . . . . . . FRONT BRAKE (DISC) INSPECTION . . . . . AIR BLEEDING . . . . . . (Refer to section GI. . . . . . . . POWER BRAKE UNIT INSPECTION . . . . . . . . . . . . . PARKING BRAKE (STICK TYPE) INSPECTION . . . REAR BRAKE (DRUM) REMOVAL/ INSTALLATION . .INDEX RANG. . . . . . . MANUAL TO. . . . BRAKE DRUM INSPECTION . . . . . . . . . . . Brake lines disconnection/connection Caution D Brake fluid will damage painted surfaces. . . . BRAKE SWITCH INSPECTION . . PARKING BRAKE SYSTEM . . . . . . . . . . . . . . . . . . . . . . DISC PAD (FRONT) REPLACEMENT . .TO. . . TORQUE FORMULAS. . . . . . . . . . . . . . . . . . and inspect leakage after the procedure has been completed. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BRAKE PEDAL REMOVAL/INSTALLATION . . . . . . . . . . . . add brake fluid. . . . . . . . . . FLUID LEVEL SENSOR INSPECTION . . . .REPAIR MANUAL PAGES. . . . . . . . VACUUM SWITCH REMOVAL/INSTALLATION . . . . . . P– 1 P– 2 P– 2 P– 2 P– 2 P– 3 P– 4 P– 4/6 P– 6 P– 7/8 P– 8 P– 9 P– 9 P–10 P–10 P–10 P–11 P–11 Brake pipe flare nut tightening D Tighten the brake pipe flare nut by using the SST (49 0259 770B). . . . . . . . . LOAD SENSING PROPORTIONING VALVE ADJUSTMENT . VACUUM LINE INSPECTION . . WHEEL CYLINDER DISASSEMBLY/ ASSEMBLY . . . . . . . . . . . . CALIPER (FRONT) DISASSEMBLY/ ASSEMBLY . . . . . .

81 in} PEDAL HEIGHT 5. inspect the following: (1) brake operation (2) fluid leakage (3) fluid level CONTINUED P–2 . replace the vacuum hose. 53—78 in·lbf} 49 0259 770B VACUUM LINE INSPECTION 1. Remove the bleeder cap and attach a vinyl tube to the bleeder screw.D.CHAPTER. drain out the fluid and retighten the screw using the SST. Tightening torque Front: 9—14 N·m {92—142 kgf·cm.63—8. Apply both suction and pressure to the engine-side hose (Gasoline) or vacuum pump side of the hose (Diesel). 6. Pedal height L. FROM.9—8.8 N·m {60—90 kgf·cm. D The brakes should be bled whenever a brake line is disconnected.H. If the disconnection point is anywhere except the master cylinder. Remove the clamps and the vacuum hose.: 214—219 mm {8. and verify that air blows only toward that side. 2. start at the point closest to the disconnection. If a hydraulic line is disconnected at the master cylinder.INDEX CONVENTIONAL BRAKE SYSTEM CONVENTIONAL BRAKE SYSTEM AIR BLEEDING Note D The reservoir should be kept 3/4 full during bleeding. start at the slave cylinder farthest from the brake master cylinder. CHECK VALVE ENG BRAKE PEDAL INSPECTION Brake Pedal Height Inspection D Verify that the distance from the center of the upper surface of the pedal pad to the floor pannel is as specified.TO.81 in} R. 2. and move to the next farthest slave cylinder until all four cylinders have been bled. 4. and then hold it in the depressed position.H.DRFT. If air flows in both directions or not at all. A second person should loosen the bleeder screw.D. MODEL . After air bleeding. 3.INDEX RANG.43—8. One person should depress the brake pedal a few times. and move to the next closest slave cylinder until all four cylinders have been bled.:219—224 mm {8. MANUAL TO. 1. Place the other end of the vinyl tube in a clear fluid-filled container.REPAIR MANUAL PAGES.BACK. Repeat steps 3 and 4 until no air bubbles are seen. 80—123 in·lbf} Rear: 5.

The brake pedal is mounted on the bracket integrated with the clutch Pedal. Loosen locknut D and turn rod C to align the holes in the fork and in the pedal. Connect the brake switch connector. 132 lbf}. 4.H.REPAIR MANUAL PAGES. The brake pedal is mounted on the bracket integrated with the clutch pedal and accelerator pedal.1—1.004—0. Loosen locknut D and turn rod C to adjust the height. CLUTCH PEDAL REMOVAL/ INSTALLATION for the brake pedal removal/installation. Depress the pedal a few times to eliminate the vacuum in the system.INDEX CONVENTIONAL BRAKE SYSTEM Brake Pedal Height Adjustment 1. Gently depress the pedal by hand until resistance is felt (approx. Tighten the bolt with locknut B so that clearance between the bolt for brake light switch A and pedal stopper is within the specification. inspect the following: (1) Air in brake system (2) Malfunction of the automatic adjuster (3) Excessive shoe clearance BRAKE PEDAL REMOVAL/INSTALLATION R.5 kgf·m. 4. 122—156 in·lbf} 5.2 in} min.BACK. D A C B Brake Pedal Play Inspection 1. inspect the pedal height and the brake light operation.039 in} Tightening torque 14—17 N·m {140—180 kgf·cm. Remove the snap pin. Pedal-to-floor Clearance Inspection 1. Disconnect the brake switch connector. inspect the pedal play and the brake light operation. 4. Tighten locknut D.H. MANUAL TO. Tightening torque 24—34 N·m {2. 3.CHAPTER.D. Remove the snap pin and clevis pin.4 lbf}) and inspect the free play. 2. 20N {2 kgf. Start the engine and verify that the distance from the floor panel to the pedal pad center is as specified when the pedal is depressed with a force of 589 N {60 kgf. Clearance 105 mm {4. Specification 0.DRFT.31 in} PEDAL-TO-FLOOR CLEARANCE 2. D C 5.INDEX RANG. Install the clevis pin and the snap pin. MODEL .4—3. Loosen locknut B and turn switch A until it does not contact the pedal. If the distance is less than specified.D. Brake Pedal Play Adjustment 1. 3. INTAKE AIR SYSTEM. FROM.0 mm {0. 6. ACCELERATOR PEDAL REMOVAL/INSTALLATION for the brake pedal removal/installation. 2. After adjustment. 2. verify that the holes in the fork and in the pedal are aligned. Refer to section F2.TO. After adjustment. 3. L. 18—25 ft·lbf} CONTINUED P–3 . Refer to section H.12—0. and reinstall the pin. Pedal play 3—8 mm {0.

87—138} SST * 12.6 N·m {100—160 kgf·cm. 2. FROM.H.BACK. 19. 113—190} * 49 0259 770B N·m {kgf·cm.H.INDEX RANG. Inspect for continuity between the terminals of the brake switch connector using the circuit tester.5 {130—220.81—15. If not as specified. 113—190} 9.7 inHg} vacuum to the power brake unit using a vacuum pump. : Continuity Condition When the brake pedal is depressed. SST R Tightening torque 9. in·lbf} 12. 2. Disconnect the brake switch connector.REPAIR MANUAL PAGES.CHAPTER.D.81—15.81—15.INDEX CONVENTIONAL BRAKE SYSTEM BRAKE SWITCH INSPECTION 1. When the brake pedal is not depressed. MANUAL TO. Loosen the adjusting nut of the SST.D.5 {130—220.) Master cylinder + Installation Note O-ring 3.TO. Remove in the order indicated in the table. 87—138} 1 Brake fluid level sensor connector Brake pipe Bracket (R.6 {100—160. MODEL . 9. 2 3 4 5 Master Cylinder Installation Note 1.9—21. Apply 66. 2.D. Install in the reverse order of removal. L. Terminal A B R.9—21. SST R SST * A B * 49 0259 770B N·m {kgf·cm. in·lbf} 49 B043 001 CONTINUED P–4 .7 kPa {500 mmHg.DRFT. MASTER CYLINDER REMOVAL/INSTALLATION 1.H. 87—138 in·lbf} 3.6 {100—160. replace the brake switch. Place the SST on the power brake unit and tighten the nut and washer.

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

INDEX CONVENTIONAL BRAKE SYSTEM Clearance at C 1.BACK. turn the nut to lengthen the power brake unit push rod an amount equal to the clearance measured at B. and measure the clearance between the adjusting nut and the SST body.CHAPTER. 3.DRFT. CLEARANCE (C) 49 B043 001 2.TO. verify that there is no continuity. 49 B043 004 49 E043 003A FLUID LEVEL SENSOR INSPECTION 1. Above MIN. Using the SSTs. Terminal A B 5.INDEX RANG. Starting with the fluid level above MIN.REPAIR MANUAL PAGES. FROM. replace the sensor. Connect an ohmmeter to the connector. 2. A B CONTINUED P–6 . : Continuity Fl id level Fluid Below MIN. Remove the brake fluid and verify that there is continuity when the level is below MIN. MODEL . 4. MANUAL TO. Push lightly on the end of the SST gauge rod. If not as specified. Disconnect the sensor connector.

Disassemble in the order indicated in the table.7—13} R 2. 18—21} N·m {kgf·cm .5 {10—15.TO. MANUAL TO. FROM. MODEL . replace the unit as a component.REPAIR MANUAL PAGES.INDEX CONVENTIONAL BRAKE SYSTEM MASTER CYLINDER DISASSEMBLY/ASSEMBLY Caution D If the master cylinder body is damaged. 8.CHAPTER.4 {20—25. 2. 1. tighten only the flange of the master cylinder. Assemble in the reverse order of disassembly.0—1. R À R R R R 1.0—2.INDEX RANG.BACK.DRFT. When securing the master cylinder in a vise. in·lbf} 1 2 3 4 5 6 7 8 9 Cap set Screw Reservoir Joint bushing Fluid level sensor Snap ring Spacer Piston guide O-ring 10 11 12 13 14 15 16 Cup Primary piston stopper Primary piston Stop screw + Assembly Note O-ring Secondary piston Master cylinder body CONTINUED P–7 .

7 kPa {500 mmHg. If the pedal height does not change. the unit is operating.7 kPa {475—500 mmHg. 2. 44 lbf} Fluid pressure 790 kPa {8 kgf/cm2. Depress the pedal with the usual force. the unit is operating. vacuum gauge. the unit is operating. and examine the installation. Stop the engine when the vacuum gauge reading reaches 66.INDEX CONVENTIONAL BRAKE SYSTEM Stop Screw and O-ring Assembly Note 1. 49 U043 004 49 U043 005 A A PEDAL DEPRESSION FORCE GAUGE VACUUM GAUGE 49 U043 006 POWER BRAKE UNIT INSPECTION Power Brake Unit Function Inspection (Simple method) Note D Replace power brake unit component as necessary. 1. With the pedal depressed. 44 lbf} Fluid pressure 8. a) Inspection for vacuum loss Unloaded condition 1. Hold the pedal down for about 30 seconds.CHAPTER. Stop the engine with the pedal held depressed. Install and tighten the stop screw. and inspect it again. 2. 3. 2. If the pedal moves down slightly. Depress the brake pedal when the vacuum reaches 66. 4. Depress the brake pedal with a force of 196 N {20 kgf. start the engine.BACK. Loaded condition 1. 114 psi} min 2. 19. 2. Note D If a problem is found. Step 2 1.0—2. Repair as necessary. 2.7—19. Push the primary piston component in full. the unit is operating.REPAIR MANUAL PAGES.3—66. MANUAL TO. inspect for damage on the check valve or vacuum hose.7 kPa {500 mmHg.3—66. 3. 2. Start the engine. Observe the vacuum gauge for 15 seconds. 2. depress the pedal a few times. conduct the test as described in the following steps. With the brake pedal depressed. 3. Stop the engine after it has run for 1 or 2 minutes.INDEX RANG.200 psi} min CONTINUED P–8 . Start the engine. If the fluid pressure is within the specification. Start the engine. Start the engine. 3. Note D Use commercially available gauges and pedal depression force gauge. 4. If the gauge shows 63. Step 3 1. D Bleed the air from the SST at gauge A.7—19.7 inHg}. 3. After bleeding the air from the SST. Start the engine. immediately after the engine starts.DRFT. and pedal depression force gauge as shown in the figure. the unit is operating.7 inHg}.7 inHg}. Install a new O-ring onto the stop screw. 18. 3. Step 1 1. Observe the vacuum gauge for 15 seconds. stop the engine when the vacuum gauge reading reaches 66. 5.TO. 44 lbf}. the unit is operating.4 N·m {20—25 kgf·cm.7 inHg}. With the engine stopped. When the engine is stopped (vacuum 0 kPa {0 mmHg. 19. 19. If the gauge shows 63. Tightening torque 2. 4. Connect the SSTs.7 kPa {475—500 mmHg. Pedal force 196 N {20 kgf. 18—21 in·lbf} (Inspection using the testers) 1.7 inHg}. b) Inspection for hydraulic pressure 1.7 kPa {500 mmHg. 18. MODEL . Pedal force 196 N {20 kgf. If the first pedal stroke is long and becomes shorter with subsequent strokes. FROM. 0 inHg}) and the fluid pressure is within the specification. Depress the pedal with the usual force.240 kPa {84 kgf/cm2. the unit is operating.

9—2.7"1. (Refer to CONVENTIONAL BRAKE SYSTEM. ft·lbf} CONTINUED P–9 . MASTER CYLINDER REMOVAL/INSTALLATION.3 {80"10. Remove the vacuum hose from the power brake unit. 18—25} N·m {kgf·m. 24—34 {2. MODEL .) 2. 3. MANUAL TO. 3. ft·lbf} R.5. Set the vacuum pump hose (commercially available on the market) onto the power brake unit as shown. L. Release the parking brake.5. The vacuum switch is functioning normally if it corresponds to the above specifications.9—2. Apply vacuum to the power brake unit using the vacuum pump (commercially available on the market) and verify the operating condition of the brake light warning light. 4.D. Remove in the order indicated in the table. 18—25} N·m {kgf·m. 3.2"0. 14—18} VACUUM SWITCH INSPECTION (DIESEL) 1.REPAIR MANUAL PAGES. 3.INDEX CONVENTIONAL BRAKE SYSTEM POWER BRAKE UNIT REMOVAL/INSTALLATION 1.4—3. FROM.7"1. 5. Turn the engine switch on. Remove the master cylinder. 24—34 {2.3 {80"10.4} Above 10.6.DRFT. inHg} Below 10.TO. 2.INDEX RANG.4—3.6.D. R Vacuum kPa {mmHg.4} 19—25 {1.BACK.2"0. Replace the vacuum switch as necessary. 14—18} Brake warning light ON OFF 6.H.H.CHAPTER. 1 2 3 4 5 6 7 8 9 Vacuum switch connector (Diesel) Vacuum hose Snap pin Clevis pin Nut Power brake unit Gasket Fork Nut R 19—25 {1. Install in the reverse order of removal.

6.5 kgf·m. 20—24 {2.BACK. MANUAL TO.6 inHg} 20—24 {2.INDEX CONVENTIONAL BRAKE SYSTEM VACUUM SWITCH REMOVAL/INSTALLATION (DIESEL) 1. If the pressure is less than the specification. 21. 15—18 ft·lbf} R DO NOT APPLY SEALANT ON THIS AREA 19—25 {1.0—2. Disconnect the vacuum hose from the vacuum pump and connect a vacuum gauge as shown in the figure. Remove the old sealant. 15—18} N·m {kgf·m.7 inHg} Maximum vacuum Engine speed 3.DRFT. inspect for the following. Caution D Do not apply sealant to the tip of the vacuum switch as a malfunction may occur.0—2.9—2. Warm up the engine.5. ft·lbf} R. 1 2 Vacuum switch connector Vacuum switch + Installation Note Vacuum Switch Installation Note 1. L. Remove in the order indicated in the table. ft·lbf} 1 2 3 4 Vacuum hose Bolt Vacuum pump O-ring CONTINUED P–10 . then inspect the vacuum.0—2. MODEL . Remove in the order indicated in the table. 15—18} N·m {kgf·m.CHAPTER. Install in the reverse order of removal.REPAIR MANUAL PAGES. Apply sealant to the area shown before installation of the vacuum switch onto the power brake unit.D. 2. 2. (1) Malfunction of the vacuum pump (2) Shortage of the lubrication oil pressure VACUUM PUMP REMOVAL/INSTALLATION (DIESEL) 1. ft·lbf} 3.3 kPa {700 mmHg.000 rpm 93. Vacuum specification (In 20 seconds) Engine speed 1. 2.3 kPa {550 mmHg. and then tighten it to the specified torque.D.500 rpm 73. 27. Install in the reverse order of removal.H.5.INDEX RANG. 2.H.TO. VACUUM PUMP INSPECTION (DIESEL) 1. FROM. Tightening torque 20—24 N·m {2. 14—18} N·m {kgf·m.

7 kgf/cm2.4 kgf/cm2. (1) Decrease dimension L if the fluid pressure is low.900 {50. Adjust main spring dimension L between the LSPV and the adjustment link by loosening and repositioning the LSPV.810 {100. LOAD SENSING PROPORTIONING VALVE REMOVAL/INSTALLATION Caution D Do not disassemble the LSPV. MODEL . Note D A change of 5 mm {0. Bleed the air from the brake system. (2) Increase dimension L if the fluid pressure is high. psi} AXLE CASING 3. Note D When applying the specified pressure.082 in} 4 4: 175. Spare tire. Inspect the tire inflations and set them to the recommended pressure as necessary. replace and adjust the LSPV.CHAPTER. include the standard vehicle tools. Install in the reverse order of removal.910—7. and tools are in designated position.530 {36. Connect pressure gauges (commercially available) to the front and rear calipers. and a full tank of fuel.900 {50.INDEX RANG. replace the LSPV as a component.5 mm {6.422} Rear pressure 2. the brake pedal must not be “double pumped” or released. Place the vehicle on level ground. If not as specified. 3. the spare wheel and tire.REPAIR MANUAL PAGES. 711} 9. 6. If not as specified. then note the reading on the rear pressure gauge.5 mm {5. 2. MANUAL TO. D Do not move the nut A.BACK. CONTINUED P–11 . Unloaded condition: Fuel tank is full.808—6. 1. recheck the fluid pressure. 148 psi} for 4 4. 4. Engine coolant and engine oil are at specified levels. LOAD SENSING PROPORTIONING VALVE ADJUSTMENT 1.DRFT.810 {100. jack. Slowly depress the brake pedal until the front pressure gauge indicates the specified pressure shown in the table.185 in} MAIN SPRING LOADED A PERSON IN DRIVER’S SEAT BOLT 4. 512} ADJUSTMENT LINK Reference value Dimension L 4 2: 147. 7.5—154.422} REAR PRESSURE FRONT PRESSURE kPa {kgf/cm2. 711} 9. kPa {kgf/cm2. read the rear pressure. 2. D Approximately two seconds after setting the front wheel cylinder fluid pressure.TO.5—182.197 in} dimension L results in a change of 853 kPa {8. FROM. After adjustment.550 {26. Prepare the vehicle with a person in the driver’s seat. psi} Front pressure 4. 5.INDEX CONVENTIONAL BRAKE SYSTEM LOAD SENSING PROPORTIONING VALVE INSPECTION 1. 124 psi} for 4 2 and 1020 kPa {10. 2. 1. 370} 3. 1. Place the unloaded vehicle on level ground. Remove in the order indicated in the table.

FROM. Machine the disc plate with it installed on the vehicle. Measure the thickness of the disc plate. LOAD SENSING PROPORTIONING VALVE ADJUSTMENT. Measure the runout at the outer edge of the contact surface of the disc pad. 2. 2. CONTINUED P–12 . Disc Plate Runout Inspection 1. Replace the pads as a set (right and left wheels) if either is at or less than the minimum thickness.BACK.9—2. SST * A SST * 12. 3.5 N·m {130—220 kgf·cm. replace the disc plate. If the runout is not within the specification.05 mm {0. Verify that there is no wheel bearing looseness.TO.08 in} min.6. 4.87 in} Minimum thickness after machining by using a brake lathe on-vehicle 22. if the disc plate is removed from the vehicle then machined.) 12. If the thickness is not within the specification.8—21.0 mm {0.INDEX CONVENTIONAL BRAKE SYSTEM 3.8—21. ft·lbf} 1 2 3 4 Brake pipe Nut Bolt Load sensing proportioning valve FRONT BRAKE (DISC) INSPECTION Disc Pad Thickness Inspection 1.REPAIR MANUAL PAGES. 3. Standard 24 mm {0. repair or replace the disc plate.5 N·m {130—220 kgf·cm. Thickness 2. 14—18} * 49 0259 770B N·m {kgf·m. Jack up the front of the vehicle and support it on safety stands. After installation.94 in} Minimum 22 mm {0. (Refer to CONVENTIONAL BRAKE SYSTEM. Remove the wheel and tires. Look through the caliper inspection hole and inspect the remaining thickness of the pads. MODEL . Runout 0. excessive runout may result.DRFT.9—2.CHAPTER. 14—18} 19—25 {1.002 in} max.8 mm {0. 113—190 in·lbf} 19—25 {1.INDEX RANG. adjust the main spring dimension. 113—190 in·lbf} Disc Plate Thickness Inspection 1.90 in} 2.6. Caution D When it is necessary to machine the disc plate. MANUAL TO.

9—3.0. FROM.CHAPTER. Remove in the order indicated in the table.2—3. Install in the reverse order of removal. 21—25} R 108—127 {10.INDEX CONVENTIONAL BRAKE SYSTEM FRONT BRAKE (DISC) REMOVAL/INSTALLATION 1.DRFT. MODEL .BACK.4—14. depress the pedal a few times. MANUAL TO. 80—94} SST N·m {kgf·m. 2.TO.0. 3.INDEX RANG.REPAIR MANUAL PAGES. 16—29} R 29—34 {2. 22—29 {2. ft·lbf} 1 2 3 4 5 Brake hose Bolt Guide pin Dust boot Caliper 6 7 8 9 Disc pad + Installation Note Plate Guide plate Mounting support CONTINUED P–13 .5. rotate the wheel by hand. After installation. and verify that the brake does not drag.

80–123} 49 0221 600C SST DISC PAD (FRONT) REPLACEMENT 1.REPAIR MANUAL PAGES. MODEL . CONTINUED P–14 . Install the disc pad. Remove in the order indicated in the table.TO. screw Caliper body Piston Disassembly Note SST N·m {kgf·m.INDEX RANG. MANUAL TO. Disassemble in the order indicated in the table. 21—25} *49 0259 770B R N·m {kgf·cm. Install in the reverse order of removal. FROM.CHAPTER. FRONT BRAKE (DISC) REMOVAL/INSTALLATION. WOOD 4 5 Piston Seal Disassembly Note D Remove the piston seal from the brake caliper using the SST.DRFT. R 29—34 {2.INDEX CONVENTIONAL BRAKE SYSTEM Disc Pad Installation Note 1.9—3. ft·lbf} Caution D Blow the compressed air slowly to prevent the piston from suddenly popping out. Assemble in the reverse order of disassembly. * SST 9—14 {92—143. 2. CALIPER (FRONT) DISASSEMBLY/ASSEMBLY 1.BACK. Disc Pad Installation Note Plate Guide plate compressed air through the hole to force the piston out of the caliper. in·lbf} 1 2 3 4 5 Piston + Disassembly Note Dust seal Piston seal + Disassembly Note Bleeder cap. Push the piston fully inward using the SST.5. D Place a piece of wood in the caliper. 2. then blow 1 2 3 Bolt Caliper Disc pad + CONVENTIONAL BRAKE SYSTEM. 2.

2. (Refer to PARKING BRAKE SYSTEM. Parking Brake Lever Stroke Inspection. REAR BRAKE (DRUM) REMOVAL/INSTALLATION 1.BACK. washer Hold pin Lower return spring Upper return spring Pawl lever spring Pawl lever 8 9 10 11 12 13 14 Adjust strut Brake shoe Parking brake cable Operating lever Brake pipe Wheel cylinder Gasket CONTINUED P–15 . 3. MODEL . Remove the brake drum.8—21.8—12.DRFT.04 in} min.TO. After installation.0 mm {0. (1) Depress the brake pedal a few times. PARKING BRAKE (STICK TYPE) INSPECTION.) 9.7 {100—130. Install in the reverse order of removal. MANUAL TO. Inspect the remaining thickness of the lining. Replace both left and right brake shoes if either is at or less than the minimum thickness. in·lbf} 1 2 3 4 5 6 7 Brake drum Hold spring.INDEX RANG. 113—190} APPLY TO SHADED EREA *49 0259 770B N·m {kgf·cm.REPAIR MANUAL PAGES.CHAPTER. Thickness 1.5 {130—220.INDEX CONVENTIONAL BRAKE SYSTEM REAR BRAKE (DRUM) INSPECTION Brake Lining Thickness Inspection 1. Remove in the order indicated in the table. 2. then verify that the brakes do not drag. (2) Inspect the parking brake lever stroke. 3. 87—112} * SST 12. FROM.

Wipe the chalk off after inspection. 22 ibf}. Before adjustment. Apply chalk to the inside of the brake drum. (2) Verify that the rear brakes do not drag when the wheels are turned by hand. screw Cylinder body CONTINUED P–16 . 2.INDEX RANG. Maximum diameter 4 2: 271. PARKING BRAKE SYSTEM BRAKE DRUM INSPECTION 1. Inspect for scratches and uneven or abnormal wear inside the drum as shown in the figure. Verify that the stroke is within the specification when the parking brake lever is pulled with a force of 98 N {10 kgf. R * 49 0259 770B N·m { kgf·cm . depress the brake pedal several times while the vehicle is moving in reverse.CHAPTER. MODEL . Repair or replace the drum as necessary. WHEEL CYLINDER DISASSEMBLY/ASSEMBLY 1.8 { 60—90 . and verify that the brake warning light illuminates. Measure the inner diameter of the drum. When repairing or replacing the drum. 2. 3. 4.BACK.5 mm {11. After adjustment. Loosen the locknut A and turn the adjustment nut B so that the stroke is within the above range. Stroke 1—7 notches 3.5 mm {10. 2.INDEX CONVENTIONAL BRAKE SYSTEM. 5. tighten the locknut A. Assemble in the reverse order of disassembly. Tightening torque 6. MANUAL TO.9—8.REPAIR MANUAL PAGES. If not as specified. Disassemble in the order indicated in the table. adjust the parking brake lever stroke. in·lbf } 1 2 3 4 5 6 Dust boot Piston Piston cap Spring Bleeder cap. 6.8 N·m {70—100 kgf·cm. 43—86 in·lbf} B A R SST * 5. Pull the parking brake lever a few times. 53—78 } R R 4. check the contact with the shoes. PARKING BRAKE (STICK TYPE) ADJUSTMENT Parking Brake Lever Stroke Adjustment 1. PARKING BRAKE SYSTEM PARKING BRAKE (STICK TYPE) INSPECTION Parking Brake Lever Stroke Inspection 1. Repair if the problem is minor. inspect the following points.67 in} 2.TO. FROM. After adjustment. pull the parking brake lever one notch.68 in} 4 4: 296.9—9.DRFT. (1) Turn the ignition (engine) switch on. 3.

BACK.) 12.TO. 3.INDEX PARKING BRAKE SYSTEM PARKING BRAKE LEVER (STICK TYPE) REMOVAL/INSTALLATION 1. (Refer to PARKING BRAKE SYSTEM.DRFT. 43—86} N·m {kgf·cm.INDEX RANG.8 {70—100. Install in the reverse order of removal. FROM.6 {130—190.8—18. MODEL .9—9. After installation. PARKING BRAKE (STICK TYPE) INSPECTION.REPAIR MANUAL PAGES. inspect the parking brake lever stroke. 113—164} 6. in·lbf} 1 2 3 4 5 6 7 8 Clip Joint pin Cable connector Parking brake switch Clip Pin Clip and joint pin Lever 9 10 11 12 13 14 15 16 Pin and clip Spring Rachet pawl Stopper Fork joint Spring Guide Rod CONTINUED P–17 . MANUAL TO.CHAPTER. 2. Remove in the order indicated in the table.

ft·lbf} CONTINUED P–18 .INDEX RANG. 12—16} 16—22 {1. Remove in the order indicated in the table. 43—86 in·lbf} 16—22 {1. FUEL SYSTEM.3.REPAIR MANUAL PAGES.6—2.3.) 2. 3. (Refer to section F1–F2.DRFT.INDEX PARKING BRAKE SYSTEM PARKING BRAKE CABLE (STICK TYPE) REMOVAL/INSTALLATION 1. (Refer to PARKING BRAKE SYSTEM. FROM.6—2.3. MODEL .6—2. inspect the parking brake lever stroke.3. 12—16} 16—22 {1.6—2. 12—16} 6. 12—16} 16—22 {1.3. After installation.6—2.9—9.6—2.9—9.8 N·m {70—100 kgf·cm. 4. PARKING BRAKE (STICK TYPE) INSPECTION.CHAPTER.BACK. 12—16} 16—22 {1. 12—16} N·m {kgf·m. Remove the under guard.) 4x2 16—22 {1. 12—16} 6.8 N·m {70—100 kgf·cm.TO.6—2.3. MANUAL TO. 43—86 in·lbf} 4x4 16—22 {1. FUEL TANK REMOVAL/INSTALLATION.3. Install in the reverse order of removal.

MANUAL TO.INDEX RANG. FROM.CHAPTER.REPAIR MANUAL PAGES.TO.INDEX PARKING BRAKE SYSTEM LHD model with F2 and G6 engine 1 2 3 4 5 6 Nut Bolt Spring Front brake cable Bolt (4 4) 4) Bracket (4 7 8 9 10 11 12 Grommet Bolt Spring (4 Clip Rear cable (left) Rear cable (right) 4) CONTINUED P-19 . MODEL .BACK.DRFT.

. Inspect the front wheel bearing play. .MAIN. . WHEEL ALIGNMENT PREINSPECTION . . .) 3. R–14 REAR SUSPENSION . . . . . . . R–13 STABILIZER AND TENSION ROD REMOVAL/INSTALLATION (4 2) . WHEEL ALIGNMENT . . WHEEL ALIGNMENT WHEEL ALIGNMENT PREINSPECTION 1. . . . . R–15 REAR SHOCK ABSORBER AND LEAF SPRING REMOVAL/INSTALLATION . . . . . . . . . . . . . . . . FRONT SHOCK ABSORBER INSPECTION . . . . . . . If a wheel is removed. . . . . . . . R–15 GENERAL PROCEDURES Wheels and tires removal/installation D The removal and installation procedures for the wheels and tires are not mentioned in this section. . . . . . . . . Suspension arms removal/installation D Tighten any part of the suspension that uses rubber bushings only after the vehicle has been lowered and unloaded*. WHEEL HUB. . . . . . . . .TO. . . . . . . Inspect the inflation of each tire. . . . . (Refer to section TD. . . . . . . . TORSION BAR SPRING AND LOWER ARM REMOVAL/INSTALLATION (4 2) . . . . . . . VEHICLE HEIGHT ADJUSTMENT. . . Adjust the bearing preload or replace bearing(s) as necessary. . . . .INDEX RANG. . . . . jack. . .) 7. . . 5. R–13/14 STABILIZER REMOVAL/INSTALLATION (4 4) . . . . . . . . . FRONT WHEEL ALIGNMENT . . . . . . . . . Inspect the wheel and tire runout at all wheels. . . . . . . FRONT SHOCK ABSORBER REMOVAL/ INSTALLATION . . R– 9/11 LOWER ARM INSPECTION . . . VEHICLE HEIGHT ADJUSTMENT . . .REPAIR MANUAL PAGES. . . . . . . . adjust the vehicle height. . . . . . . . . . . . . . . . Engine coolant and engine oil are at specified levels. . . . . FRONT AXLE (4 2). . . .INDEX SUSPENSION GENERAL PROCEDURES . referring to section TD. . STEERING KNUCKLE INSPECTION or FRONT AXLE (4 4). WHEEL HUB. . * Unloaded condition: Fuel tank is full. . . Shake the vehicle to settle the suspension. The difference in height between the left and right sides from the center of the wheel to the fender brim must not exceed 10 mm {0. . . . . .DRFT. R–12 UPPER ARM INSPECTION . . . 6. Inspect the ball joints and steering linkage for excessive looseness. . . Spare tire. . FROM. R–1 R–1 R–1 R– 2/3 R–3 R–3 R–5 R–5 R– 6/8 TORSION BAR SPRING AND LOWER ARM REMOVAL/INSTALLATION (4 4) . . . . . and set to the recommended pressure. (Refer to FRONT SUSPENSION. Place the vehicle on level ground with no luggage and passenger load. . (Refer to section M. . . CONTINUED R–1 .) 4. . . R–11 UPPER ARM REMOVAL/INSTALLATION . . . If not within the specification. . . MANUAL TO. 2. . . MODEL . . . . and tools are in designated position. retighten it to the specified tightening torque. Wheels and Tires. . . . SUSPENSION. . . . . . as necessary. . FRONT SUSPENSION . . STEERING KNUCKLE INSPECTION.BACK. . . . .39 in}.

Note D One turn of the tie rod (both sides) changes the toe-in by about 30 mm {1. After adjustment.TO.12"0. Engine coolant and engine oil are at specified level.REPAIR MANUAL PAGES.INDEX WHEEL ALIGNMENT FRONT WHEEL ALIGNMENT Specifications Item Total toe toe-in in Maximum steering g angle Camber angle*2 Caster angle*3 Steering axis inclination (reference value) *1 *2 *3 Specification 4 2 (mm {in}) (degree) Inner Outer 0! 16’ "16’ 35! 00’ 33! 00’ +2! –3! +2! –3! 4 4 3"3 {0.18 in}. Tightening torque 69—78 N·m {7. Turn the tie rods by the same amount in the opposite direction. 29—43 ft·lbf} 4 2 ADJUSTING BOLT 4 4 ADJUSTING BOLT CONTINUED R–2 .12} 0! 14’ "14’ 33! 30’ 30! 00’ +2! –3! +2! –3! Front wheel heel alignment (*1Unloaded condition) 0! 56’ "30’ 1! 37’ "45’ 8! 04’ 1! 06’ "30’ 2! 02’ "45’ 10! 15’ Fuel tank is full. Tighten the tie-rod end locknuts. 2. To increase the toe-in. MODEL . Difference between left and right must not exceed 45’. jack. 3.0 kgf·m. D The left and right tie rods are both right threaded. 51—57 ft·lbf} TIE ROD Maximum Steering Angle Adjustment 1.CHAPTER. and tools are in designated position. Loosen the tie-rod end locknuts. 3.INDEX RANG. Loosen the adjusting bolt locknut.BACK. Spare tire.0—8.0—6. Turn the adjusting bolt to provide the correct turning angle. 2.DRFT. FROM. Difference between left and right must not exceed 30’. Tightening torque 40—58 N·m {4. turn the right tie rod toward the front of the vehicle and the left tie rod equally toward the rear.0 kgf·m. MANUAL TO. Total Toe-in Adjustment 1. tighten the locknut to the specified torque.

Tightening torque 94—116 N·m {9.039} 1.039 in} results in a change of about 30’.063} 2. 7 8 9 10 11 Thickness (mm {in}) 1.6 {0. Stretch Cab Double Cab Tire size 205R16 235/75R15 205R16 235/75R15 Vehicle height 519 {20.157} 0.3} 510 {20.0 {0.5—11.6 {0. No.6—11 FRONT SUSPENSION VEHICLE HEIGHT ADJUSTMENT 1. D Caster: A change of shim thickness (at front or rear only) of 1 mm {0. Inspect the front and rear tire pressure and adjust it as necessary. After adjustment.TO.9 kgf·m. tighten the upper arm shaft bolt to the specified torque.079} 3.1} 506 {19.DRFT.1—5 No. 2.0 {0.8} 422 {16.2 {0. D Shims No. Stretch Cab Double Cab 4 4 Cab type Regular g Cab.6 {0. Place the vehicle on level ground.CHAPTER. MANUAL TO.039} 1.39 in} max.039 in} results in a change of about 15’. MODEL .0 {0.REPAIR MANUAL PAGES. FRONT SUSPENSION Caster and Camber Adjustment 1.0 {0. 2. .0 {0.2 {0.INDEX RANG. Loosen the upper arm shaft bolt and insert or remove adjustment shims to provide the correct angle. Standard vehicle height (reference value) 4 2 Cab type mm {in} Vehicle height 427 {16.1—5 are used on either side.BACK. Do not use more than one.6—11 are used at the front and rear of either sides. D Camber: A change of shim thickness (at front and rear) of 1 mm {0.157} Regular Cab. FRONT Left/right difference 10 mm {0. 69—86 ft·lbf} CONTINUED R–3 .063} 2.024} No.9} Note D Shims No.INDEX WHEEL ALIGNMENT.4} 515 {20. 1 2 3 4 5 6 Thickness (mm {in}) 1.6} Adjustment shim No. Do not use more than two. FROM.126} 4.079} 3. 3.0 {0. Measure the distance from the center of each front wheel to the fender brim.126} 4.

REPAIR MANUAL PAGES. 4 2 4 4 ANCHOR BOLT ANCHOR BOLT CONTINUED R–4 . FROM.BACK.INDEX RANG.CHAPTER.TO. MODEL . adjust the vehicle height by turning the torsion bar spring anchor bolt. If the difference between left and right is not within the specification. MANUAL TO.DRFT.INDEX FRONT SUSPENSION 1.

Remove the front shock absorber from the vehicle. 3. 5. 2. Remove in the order indicated in the table. Inspect the rubber bushing for deterioration and wear. bushing 3 4 5 Bolt Washer and nut Shock absorber Nut Installation Note D Tighten the nut so that the exposed thread of the shock absorber piston is 6—8 mm {0.CHAPTER. 6—8 mm {0. Install in the reverse order of removal.24—0. MANUAL TO.31 in}.BACK.2.DRFT. Inspect for damage and oil leakage. 2.TO.INDEX RANG.24—0. CONTINUED R–5 . FRONT SHOCK ABSORBER INSPECTION 1.REPAIR MANUAL PAGES. MODEL . Verify that the operational force does not change and that there is no unusual noise. Verify that the piston extends fully at a normal speed. 41—59} N·m {kgf·m. ft·lbf} 1 2 Nut + Installation Note Retainer. Compress the shock absorber piston and release it.31 in} 55—80 {5. 4.INDEX FRONT SUSPENSION FRONT SHOCK ABSORBER REMOVAL/INSTALLATION 1.6—8. Compress and extend the shock absorber piston at least three (3) times. FROM.

DRFT. MODEL . 3. MANUAL TO.0.REPAIR MANUAL PAGES. Inspect the vehicle height and adjust it as necessary. APPLY THREAD LOCKING COMPOUND APPLY THREAD LOCKING COMPOUND 118—156 {12.INDEX FRONT SUSPENSION TORSION BAR SPRING AND LOWER ARM REMOVAL/INSTALLATION (4 2) 1. Remove in the order indicated in the table. Install in the reverse order of removal. and nut + Installation Note Lower arm Bound bumper. 2. washer. washer. 87—115} 118—156 {12. and nut Rubber bushing + Removal Note + Installation Note Tension rod bolt Stabilizer bolt.BACK.0. 87—115} SST R N·m {kgf·m.INDEX RANG. washer. and nut Bolts and washer (ball joint) Lower arm ball joint Clip + Installation Note Lower arm ball joint boot 14 15 16 17 18 19 20 21 6 7 8 9 10 CONTINUED R–6 .0—16. FROM. and nut (shock absorber) Anchor bolt + Removal Note + Installation Note Anchor swivel Bolt and washer Torsion bar component Anchor arm Torsion bar spring + Removal Note + Installation Note 11 12 13 Torque plate Lower arm spindle.TO. bushing.CHAPTER. spacer. retainer. ft·lbf} 1 2 3 4 5 Cotter pin Nut Lower arm ball joint/Knuckle arm + Removal Note Bolt.0—16.

Spacer And Nut Installation Note D Tighten the nuts so that 18—21 mm {0. FROM.71—0.TO. MATCHING MARK 18—21 mm {0. Clip Installation Note 1. MODEL . Retainer.DRFT. KNUCKLE 49 T028 3A0 49 U034 208 Anchor Bolt Removal Note D Mark the anchor bolt and swivel for reference during installation.82 in} of thread is exposed at the end of the bolt. Install the clip in the dust boot groove.INDEX RANG. Bushing.71—0.CHAPTER.82 in} Torsion Bar Spring Removal Note D Mark the torsion bar spring and anchor arm and the torsion bar spring and torque plate for reference during installation. MANUAL TO. 49 UB39 615 CONTINUED R–7 . MATCHING MARK MATCHING MARK 49 UB39 615 Rubber Bushing Removal Note D Remove the rubber bushing from the body using the SST.BACK. Stabilizer Bolt. Install the SST to the ball joint stud with the stud stands straight up.REPAIR MANUAL PAGES. 2. Rubber Bushing Installation Note D Install a new bushing using the SST.INDEX FRONT SUSPENSION Lower Arm Ball Joint/Knuckle Arm Removal Note D Separate the ball joint from the knuckle arm using the SST.

TO. FROM. and tighten it until the marks made during removal are aligned.BACK.3 turns. Before installation. (3) Install the anchor bolt and tighten it 27. (2) Install the anchor arm so that the angle A is 34° "4. MANUAL TO.INDEX RANG. MATCHING MARK MATCHING MARK Anchor Bolt Installation Note D Install the anchor bolt. A CONTINUED R–8 . MATCHING MARK Note D If the anchor bolt was not marked during removal. R: Right bar 2.DRFT.CHAPTER.INDEX FRONT SUSPENSION Torsion Bar Spring Installation Note 1.5°. Align the marks made during removal. MODEL . check the identification mark on the end of the torsion bar spring. install it as follows: (1) Lower the front suspension until the upper arm contacts the rebound stopper. and connect the torsion bar spring to the torque plate. L: Left bar.REPAIR MANUAL PAGES.

INDEX FRONT SUSPENSION TORSION BAR SPRING AND LOWER ARM REMOVAL/INSTALLATION (4 4) 1.0. And Nut Installation Note Lower arm Bound bumper. 2. MANUAL TO. Clip Installation Note Lower arm ball joint boot Lower arm bushing + Removal Note + Installation Note 4 5 6 7 8 9 15 16 17 18 19 10 20 21 11 12 CONTINUED R–9 . washer and nut Stabilizer bolt. washer and nut Lower arm ball joint Clip + FRONT SUSPENSION. spacer and nut + FRONT SUSPENSION. FROM. TORSION BAR SPRING AND LOWER ARM REMOVAL/INSTALLATION (4 2). 3.DRFT. Inspect the vehicle height and adjust it as necessary. Retainer. Install in the reverse order of removal.INDEX RANG. 87—115} APPLY THREAD LOCKING COMPOUND SST R R 1 2 3 Cotter pin Nut Lower arm ball joint/Knuckle arm + FRONT SUSPENSION.REPAIR MANUAL PAGES. Spacer. TORSION BAR SPRING AND LOWER ARM REMOVAL/INSTALLATION (4 2).TO. Stabilizer Bolt. TORSION BAR SPRING AND LOWER ARM REMOVAL/INSTALLATION (4 2).0—16. washer and nut (shock absorber) Anchor bolt and washer + Installation Note Anchor swivel Bolt and washer Torsion bar spring component Anchor arm + Removal Note + Installation Note Torsion bar spring + Removal Note + Installation Note Torque plate Lower arm spindle (rear). MODEL .0. washer.0—16. and nut Bolt. Bushing. washer and nut 13 14 Lower arm spindle (front). Remove in the order indicated in the table. Remove the driveshaft snap ring. 87—115} 118—156 {12.BACK. Lower Arm Ball Joint/Knuckle Arm Removal Note Bolt. 4. 118—156 {12. retainer.CHAPTER. bushing.

MANUAL TO. R: Right bar 2. Torsion Bar Spring Installation Note 1.CHAPTER. inspect the identification mark on the end of the torsion bar spring. 2. Lower Arm Bushing Installation Note 1. and install the anchor arm onto the torsion bar spring. MODEL .INDEX FRONT SUSPENSION Anchor Arm Removal Note D Mark the anchor arm and body for reference during installation. 49 U034 2A0 Torsion Bar Spring Removal Note D Mark the torsion bar spring and anchor arm and the torsion bar spring and torque plate for reference during installation.REPAIR MANUAL PAGES. Install the bushing using the SST. Align the marks made during removal.BACK. Before installation.TO. L: Left bar.DRFT. and connect the torsion bar spring to the torque plate. Apply soapy water to the new bushing. FROM. Lower Arm Bushing Removal Note D Remove the lower arm bushing using the SST.INDEX RANG. Anchor Arm Installation Note D Align the marks made during removal. 49 U034 2A0 CONTINUED R–10 .

0—3.CHAPTER. MODEL . A LOWER ARM INSPECTION 1.TO. Inspect for damage. Remove the lower arm from the vehicle. install it at follows: (1) Lower the front suspension until the upper arm contacts the rebound stopper.4—7.INDEX RANG.5 kgf. (3) Replace it if not within the specification.BACK. Note D If the anchor bolt was not marked during removal. Pull scale reading 20—34 N {2. (1) Rotate the ball joint five times. FROM.INDEX FRONT SUSPENSION Anchor Bolt Installation Note D Install the anchor bolt. Check the ball joint rotation torque. (3) Install the anchor bolt and tighten it 26.REPAIR MANUAL PAGES.9 turns. MANUAL TO. cracks. 3. and measure the rotation torque using a pull scale.DRFT. and bending. (2) Connect the SST to the ball stud. and tighten it until the marks made during removal are aligned. (2) Install the anchor arm so that the angle A is 60°"4. 2. 4.5°.7 lbf} 49 0180 510B CONTINUED R–11 .

49 T028 3A0 Clip Installation Note 1.CHAPTER. Install the clip in the dust boot groove. 3. Remove in the order indicated in the table. MODEL . amount and position of the shims so that they are reinstalled in the correct positions. 2.INDEX FRONT SUSPENSION UPPER ARM REMOVAL/INSTALLATION 1. Install in the reverse order of removal. CONTINUED R–12 .TO. Install the SST to the ball joint stud with the stud stands straight up.REPAIR MANUAL PAGES. 2. FROM. Inspect the wheel alignment and adjust it as necessary. KNUCKLE 49 U034 209 Adjustment Shim Removal Note D Note the number.DRFT.BACK.INDEX RANG. R SST 1 2 3 4 5 Clip Cotter pin and nut Upper arm ball joint/Knuckle arm + Removal Note Bolt and washer Adjustment shim + Removal Note 6 7 8 9 10 Upper arm component Bolt and washer Upper arm ball joint Clip + Installation Note Upper arm ball joint boot Upper Arm Ball Joint/Knuckle Arm Removal Note D Separate the upper arm ball joint from the knuckle arm using the SST. MANUAL TO.

Pull scale reading 5. retainer and spacer Bolt 6 7 8 9 10 11 12 Stabilizer bracket Bushing Stabilizer bar Tension rod nut + Installation Note Bushing and retainer Bolt Tension rod 2 3 4 5 CONTINUED R–13 . FROM.INDEX RANG. 2.0. MODEL . And Nut Installation Note Retainer Bolt Bushing.BACK. cracks.0—24 N {0. Inspect for damage. Install in the reverse order of removal. TORSION BAR SPRING AND LOWER ARM REMOVAL/INSTALLATION (4 2). (1) Rotate the ball joint five times. Remove the upper arm from the vehicle. 1. 49 0180 510B 22—26 {2. Bushing. Remove in the order indicated in the table.CHAPTER. Check the ball joint rotation torque. ft·lbf} 1 Nut + FRONT SUSPENSION.REPAIR MANUAL PAGES.5 kgf. 69—94} N·m {kgf·m. 3. 2.5—11. 16—19} APPLY THREAD LOCKING COMPOUND 94—116 {9. and measure the rotation torque using a pull scale. (3) Replace it if not within the specification. Retainer. 69—86} 94—127 {9. MANUAL TO.9. Stabilizer Bolt.TO.2—5.5—13.2—2. (2) Connect the SST to the ball stud. Spacer.5—2.DRFT.5 lbf} STABILIZER AND TENSION ROD REMOVAL/INSTALLATION (4 2) 1. and bending.7.INDEX FRONT SUSPENSION UPPER ARM INSPECTION 1.

STABILIZER AND TENSION ROD REMOVAL/INSTALLATION (4 2).DRFT. L STABILIZER REMOVAL/INSTALLATION (4 4) 1. bushing.7.BACK.INDEX RANG. MANUAL TO. Remove in the order indicated in the table. MODEL .INDEX FRONT SUSPENSION Tension Rod Nut Installation Note D Tighten the tension rod nuts so that length L is 98. FROM.88 in}. 2.2—2.5 mm {3. Nut Installation Note Retainer and bushing Bolt Retainer and bushing 5 6 7 8 9 Retainer.TO. Install in the reverse order of removal. 22—26 {2.CHAPTER.REPAIR MANUAL PAGES. and spacer Bolt Stabilizer bracket Bushing Stabilizer bar 2 3 4 CONTINUED R–14 . 16—19} N·m {kgf·m. ft·lbf} 1 Nut + FRONT SUSPENSION.

BACK.7. 58—72} N·m {kgf·m. retainer.INDEX RANG.5} 54—73 {5.DRFT.CHAPTER. 44—57} R APPLY THREAD LOCKING COMPOUND R 20—26 {2.0.5—7.5—8. Install in the reverse order of removal. raise or lower the jack as necessary. 4 2 R 64—78 {6. MANUAL TO.0—10.5. 48—57} 59—78 {6. and bushing Nut. FROM. and bushing Shock absorber Nut and washer Nut and washer U-bolt Spring clamp Stopper rubber Bolt and washer 10 11 12 13 14 15 Spring pin Nut and washer Shackle pin Shackle plate Leaf spring component Leaf spring bushing + Removal Note + Installation Note CONTINUED R–15 . ft·lbf} 1 2 3 4 5 6 7 8 9 Nut. Remove in the order indicated in the table.REPAIR MANUAL PAGES. MODEL . retainer. washer.0—8.0. 2.0. 40—54} 78—98 {8. washer.INDEX REAR SUSPENSION REAR SUSPENSION REAR SHOCK ABSORBER AND LEAF SPRING REMOVAL/INSTALLATION 1. While supporting the differential casing with a jack.0—2. Support the frame with safety stands and place a jack under the differential casing.TO. 15—19.

44—57} R 78—98 {8. FROM.0.0—10.1} APPLY THREAD LOCKING COMPOUND R 64—78 {6.1—11. retainer.5} N·m {kgf·m.CHAPTER. MANUAL TO.1—112 {10. 58—72} 20—26 {2. MODEL . and bushing Nut.5.7.DRFT.0.INDEX RANG. 15—19.TO.0—2. retainer.INDEX REAR SUSPENSION 4 4 99. and bushing Shock absorber Nut and washer Nut and washer U-bolt Set plate Spring clamp Stopper rubber 11 12 13 14 15 16 17 Bolt and washer Spring pin Nut and washer Shackle pin Shackle plate Leaf spring component Leaf spring bushing + Removal Note + Installation Note CONTINUED R–16 . 48—57} 59—78 {6.5—8.0. ft·lbf} 1 2 3 4 5 6 7 8 9 10 Bolt and nut Washer. washer.1—83.0—8. 73.REPAIR MANUAL PAGES.BACK.

DRFT.CHAPTER.TO. FROM. CONTINUED R–17 .INDEX RANG.BACK. MANUAL TO.INDEX REAR SUSPENSION Leaf Spring Bushing Removal Note D Secure the leaf spring in a vise and remove the bushing using a chisel.REPAIR MANUAL PAGES. Leaf Spring Bushing Installation Note D Press in the bushing using a suitable pipe. MODEL .

. . . FILAMENT INSPECTION . . . . . . . . . . . . . . . . . . . . . . .BACK. . . . . BONNET ADJUSTMENT . . . . . . . . . . . . . DOOR LOCK TIMER UNIT REMOVAL/INSTALLATION . . . . . . . . . . . . . . . . . REAR WINDOW DEFROSTER RELAY INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SIDE PROTECTOR REMOVAL . . . . . . . REARVIEW MIRROR . . OUTSIDE MIRROR . BUMPER . . . . . . . . . DOOR LOCK STRIKER REMOVAL/INSTALLATION . . POWER WINDOW SUBSWITCH INSPECTION . TAILGATE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . REAR BELTLINE MOLDING REMOVAL/INSTALLATION . . . . . . FRONT BUMPER REMOVAL/INSTALLATION .REPAIR MANUAL PAGES. . . . . . . . . . . . . . WINDSHIELD UPPER MOLDING REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . POWER OUTSIDE MIRROR REMOVAL/INSTALLATION . . . . . . . . . . . . . . . REGULATOR HANDLE INSTALLATION . . . . . . . . . . . . . REAR DOOR ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FRONT BUMPER DISASSEMBLY/ASSEMBLY . . . . FILAMENT REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MODEL . . FROM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FUEL-FILLER LID AND OPENER . . . . . . . . . . . FRONT DOOR REMOVAL/INSTALLATION . . . . . . . . . . BODY S– 2 S– 2/3 S– 3 S– 4 S– 4 S– 5 S– 5 S– 6 S– 7 S– 7 S– 8/9 S– 9 S– 9 S– 9 S– 9 S–10 S–10 S–10/12 S–12 S–12/13 S–13 S–13 S–13/14 S–14 S–14 S–15 S–15 S–15 S–15 S–15 S–15 S–16 S–16 S–17 S–19 S–19 S–19 S–19 S–19 S–19 S–20 S–20/21 EXTERIOR ATTACHMENT . . . . . . . . . . . . . . . . . . . . . REAR POWER WINDOW REGULATOR REMOVAL/INSTALLATION . . . . POWER WINDOW MAIN SWITCH REMOVAL/INSTALLATION . . . DOOR LOCK TIMER UNIT INSPECTION . . . . . . . . . . . . . . . . . . . . . . POWER OUTSIDE MIRROR INSPECTION . . . . . . . . . . . . . . . . . . . . .TO. . . . . . . . . . . RADIATOR GRILLE REMOVAL/INSTALLATION . . REAR WINDOW DEFROSTER . . . . S–21 S–21 S–21 S–21/22 S–22 S–22/23 S–23 S–23 S–23 S–24 S–24 S–24 S–24 S–24 S–24 S–24 S–25 S–25 S–25 S–25 S–25 S–25/26 S–26 S–26 S–27 S–27 S–27 S–27 S–27 S–27/28 S–28 S–28 S–28 S–29 S–29/30 S–30/31 S–32 S–33 S–33 S–34 S–1 CONTINUED . . . . . . . . . . . . . . . REAR BUMPER DISASSEMBLY/ASSEMBLY . . . . . . . . . . . . . . POWER WINDOW MOTOR INSPECTION . . REAR WINDOW DEFROSTER RELAY REMOVAL/INSTALLATION . . . . . FRONT FENDER PANEL . . . OVER FENDER REMOVAL/INSTALLATION . . . . . . . . . . QUARTER WINDOW GLASS REMOVAL/INSTALLATION . . . . . . . . . . . . . . . . COWL GRILLE REMOVAL/INSTALLATION . . . . . . . . . . . WINDSHIELD SIDE MOLDING INSTALLATION . DOOR LOCK ACTUATOR INSPECTION . . . . FRONT POWER WINDOW REGULATOR DISASSEMBLY/ASSEMBLY . . . . . DOOR LOCK ACTUATOR REMOVAL/INSTALLATION . . . . . . . . . . . . . . . . . . . . . WINDOW GLASS . . . . . . . . . . . . . . . . . . . . . . .INDEX PAGE 1 OF 2 BONNET . . . . . . . . . ROOF MOLDING REMOVAL/INSTALLATION . . . . . WINDSHIELD UPPER MOLDING INSTALLATION . . . . . . . . . .MAIN. FRONT POWER WINDOW REGULATOR REMOVAL/INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MOLDING . . . . . . DASHBOARD AND CONSOLE . . . . . . . . . . . . . . . MANUAL OUTSIDE MIRROR REMOVAL/INSTALLATION . . . . . . POWER OUTSIDE MIRROR SWITCH REMOVAL/INSTALLATION . . . . . . . . . . . FUEL-FILLER LID REMOVAL/INSTALLATION . . . . . . . . . . . . . . . . REAR BUMPER REMOVAL/INSTALLATION . . DOOR KEY CYLINDER SWITCH REMOVAL/INSTALLATION . . . . . . DOOR LOCK-LINK SWITCH INSPECTION . . FRONT DOOR ADJUSTMENT . . . . . . . POWER WINDOW SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FRONT DOOR DISASSEMBLY/ASSEMBLY . . . . . . . . . . . . . . . . .DRFT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FRONT BELTLINE MOLDING REMOVAL/INSTALLATION . . . REAR WINDOW GLASS INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . SIDE PROTECTOR INSTALLATION . . . . . WINDSHIELD REMOVAL . . . . REAR WINDOW DEFROSTER SWITCH INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BONNET REMOVAL/INSTALLATION . . . . . . . . . . . REARVIEW MIRROR REMOVAL/INSTALLATION . . . . . . . . . . . . . . . . . . . . . POWER OUTSIDE MIRROR SWITCH INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . POWER WINDOW SUBSWITCH REMOVAL/INSTALLATION . . POWER WINDOW MAIN SWITCH INSPECTION . . . . . . . . . . . . . . . . . POWER DOOR LOCK SYSTEM . . TAILGATE DISASSEMBLY/ASSEMBLY . . . . . . . . . . . . . . . . . REAR POWER WINDOW REGULATOR DISASSEMBLY/ASSEMBLY . . . . . . . . . . . . . WINDSHIELD INSTALLATION . . . REAR DOOR REMOVAL/INSTALLATION . . . . . . . . ROPE HOOK REMOVAL/INSTALLATION . . . . . . . . . . . . . . DOOR . . . . . . . . . . . . . . DOOR KEY CYLINDER SWITCH INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . REGULATOR HANDLE REMOVAL . . . . . . . . . . . . . . DOOR LOCK-LINK SWITCH REMOVAL/INSTALLATION . . . . . . REAR WINDOW DEFROSTER SWITCH REMOVAL/INSTALLATION . . . . . . . REAR DOOR DISASSEMBLY/ASSEMBLY . MANUAL TO. . . . . . . . . . . . . WINDSHIELD SIDE MOLDING REMOVAL . . . . . . . . . . . . . . . . . . . REAR WINDOW GLASS REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FRONT FENDER PANEL REMOVAL/INSTALLATION . . . . . . . . . . . .INDEX RANG. . . . . . . . . WINDSHIELD GARNISH REMOVAL/INSTALLATION . . . . FUEL-FILLER LID ADJUSTMENT . . . . . . . . . . .

. . . . . . . . . .INDEX RANG. . S–48 FRONT SEAT REMOVAL/INSTALLATION . . . .INDEX BONNET PAGE 2 OF 2 DASHBOARD REMOVAL/INSTALLATION . . .CHAPTER. . . . . . . . . TRIM . . . . . . . .9—10. . . . . . S–54 SEAT WARMER UNIT INSPECTION . . . . . . . . . . . . . . . . . . . . . . S–54 RANG. . . . . . . . . . . . . . . . . . . . . . FRONT CONSOLE REMOVAL/INSTALLATION . . . . . . . . . . . . .REPAIR MANUAL PAGES. . . . . . . .INDEX BONNET Warning D Removing the bonnet without supporting it can be dangerous. Install in the reverse order of removal. . . S–41 HEADLINER . . . . . . . . . S–49/50 CABLE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . .REPAIR MANUAL PAGES. . . . .TO. . . . . . . . . . S–54 SEAT WARMER SWITCH INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . (Refer to FRONT FENDER PANEL. . . . . . . . . . . S–51 REAR SEAT REMOVAL/INSTALLATION . . . . . . . . . . COLUMN COVER REMOVAL/INSTALLATION . . . . . S–42 FLOOR COVERING . . . . . . . . . . REAR SCUFF PLATE REMOVAL/INSTALLATION . S–46 BUCKLE SWITCH INSPECTION . . . . BODY S–34 S–35 S–36 S–36 S–36 S–36 S–36 S–37 S–37 S–37 S–38 S–38 S–38 S–38 S–38 S–39 S–39 S–39 C-PILLAR TRIM REMOVAL/INSTALLATION . . . . .5—95. . . . . . GLOVE COMPARTMENT REMOVAL/INSTALLATION . . . S–41 REAR DOOR TRIM REMOVAL/INSTALLATION . . BONNET REMOVAL/INSTALLATION 1. . . . . S–44 SEAT BELT REMOVAL/INSTALLATION . . . . . . . . . (Refer to BONNET ADJUSTMENT. . . MODEL . . . . . . . . . . . . B-PILLAR UPPER TRIM REMOVAL/INSTALLATION . . . . . . .) 3. . A-PILLAR TRIM REMOVAL/INSTALLATION . . .4} N·m {kgf·cm. . . . . . . . S–51/52 REAR SEAT DISASSEMBLY/ASSEMBLY . . . .7 {80—110. . DASHBOARD MEMBER REMOVAL/INSTALLATION . . . . . . . Always perform these procedures together with at least another person. . . . . FRONT SIDE TRIM REMOVAL/INSTALLATION . 2. The bonnet may fall and injure you. . . . . . . . . . . . . . .CHAPTER. . . . . . . . . . . S–48 FRONT SEAT DISASSEMBLY/ASSEMBLY . . . . . . . . . . . . . . . . MANUAL TO. . . . . . . . . . . . . . . . . . . . . . . . . . . FROM. .0—3. DASHBOARD DISASSEMBLY/ASSEMBLY . . MODEL . . . . . . . . . S–42 FLOOR COVERING REMOVAL/INSTALLATION . . . . . . . . . . REAR CONSOLE REMOVAL/INSTALLATION . . . . . .TO. . . S–54 SEAT WARMER SWITCH INSPECTION . B-PILLAR LOWER TRIM REMOVAL/INSTALLATION . . . . . . . . Remove in the order indicated in the table. in·lbf} 1 2 3 4 Shroud seal weatherstrip Bonnet Bonnet hinge Bonnet stay S–2 CONTINUED . B-PILLAR TRIM REMOVAL/INSTALLATION . . . . . . . . . . S–45/46 BUCKLE REMOVAL/INSTALLATION . . . . . . . . S–42 HEADLINER REMOVAL/INSTALLATION . . . . . 6. . . . . . . . S–44/45 SEAT BELT INSPECTION . . . . . . remove the front fender panel. . MANUAL BACK. . . . . . . S–40 FRONT DOOR TRIM REMOVAL/INSTALLATION . To remove the bonnet lock. . S–42/43 SEAT BELT . . . . . . . . S–39/40 QUARTER LOWER TRIM REMOVAL/INSTALLATION . FRONT FENDER PANEL REMOVAL/INSTALLATION. . . FRONT SCUFF PLATE REMOVAL/INSTALLATION . . S–40 BACK LOWER TRIM REMOVAL/INSTALLATION . . . . . . . . . . 5. . FROM. . . . . .INDEX Á À Å A A Â Ã Ä Æ 7. remove the radiator grille. . Adjust the bonnet. . . . . . . . . . . . S–52/53 SEAT WARMER SWITCH REMOVAL . . . REAR CONSOLE DISASSEMBLY/ASSEMBLY . . . . . . . . FRONT CONSOLE DISASSEMBLY/ASSEMBLY . . . To remove the bonnet hinge. . . . . . . . . . . . . . . . . . . . 27—34} TO. . . . . . . . S–40 BACK UPPER TRIM REMOVAL/INSTALLATION . . . . . . S–47 SEAT . . . . . . . . . .BACK. . . . .9 {30—40. . METER HOOD REMOVAL/INSTALLATION . . . . . . . . . . . . . . . . S–39 QUARTER UPPER TRIM REMOVAL/INSTALLATION . . . . . . . . .) 3. . . . . . . . . . . . . . . . .DRFT. . . . . .DRFT. . . . . Pull out the windshield washer pipe. . . . . . . . . . . 69. . . . 4.

2} D D E E B B C C A A a e b .03 in} (sec. c.09—0. BOLT 5 6 7 Bonnet lock Bonnet release lever Bonnet release cable BONNET ADJUSTMENT 1.28—0.BACK. C—C SEC. CONTINUED S–3 . 50 {2.DRFT. C—C) e: 6.3—0. A—A SEC.) Gap Adjustment 1.3 mm {–0.TO. Tighten the bonnet lock installation bolts.20 in} b: –1.0—10.INDEX BONNET Height Adjustment 1.0} 30 {1.3—0.3 mm {0. Tighten the bonnet installation bolts.03 in} (sec.01 in} (sec.51 in} 2.7—5. MANUAL TO. MODEL . B—B SEC. FROM.09—0.CHAPTER.INDEX RANG. E—E mm {in} 2. Measure the gap and height between the bonnet and the body. B—B) d: –2.0—13. If not as specified. A—A) c: –2.8 mm {–0. Clearance a: 2.8—0. D—D SEC. (Refer to Gap Adjustment. d f SEC.0 mm {0. adjust the gap and height. Loosen the bonnet lock installation bolts and move the bonnet lock to reposition the bonnet.11—0. BOLT 2.24—0.REPAIR MANUAL PAGES. Loosen the bonnet installation bolts and reposition the bonnet.) (Refer to Height Adjustment.07—0.0 mm {0.8 mm {–0.39 in} f: 7.

3. Remove the front side turn light. Remove the front flap. 60. B B A A 6.INDEX FRONT FENDER PANEL FRONT FENDER PANEL FRONT FENDER PANEL REMOVAL/INSTALLATION 1.REPAIR MANUAL PAGES. Install in the reverse order of removal. FROM.CHAPTER.8—86. 7. Remove in the order indicated in the table.80 N·m {70—100 kgf·cm. MANUAL TO. 4.DRFT. 2. 6.BACK. Disconnect the negative battery cable.7 in·lbf} 1 2 Mud guard Front fender panel CONTINUED S–4 . Remove the front bumper.TO. MODEL .87—9. 5.INDEX RANG. Remove the front turn light.

remove the speaker. Adjust the front door. (Refer to FRONT FENDER PANEL.) 5. 1 2 3 4 5 Front door harness ☞ Removal Note Checker pin Front door hinge Front door Checker CONTINUED S-5 .) 4. FROM.BACK. SPEAKER REMOVAL/INSTALLATION. Symbol A B C D E Connector name Passenger's side Driver's side Door lock-link switch Door lock actuator Power window main Power window switch subswitch Power outside mirror Front power window regulator Speaker ← ← ← 2. Remove the rubber boot and pull out the door harness. remove the front fender panel. MANUAL TO.DRFT.) 3. 3. Disconnect the connectors indicated in the table. (Refer to section T. Remove the door screen. (Refer to FRONT DOOR DISASSEMBLY/ASSEMBLY. 2.INDEX Front Door Harness Removal Note 1. if equipped.) RANG. Disconnect the negative battery cable. 7. Remove in the order indicated in the table.REPAIR MANUAL PAGES.INDEX DOOR DOOR FRONT DOOR REMOVAL/INSTALLATION 1. Install in the reverse order of removal.TO. To remove the checker. (Refer to FRONT DOOR ADJUSTMENT. AUDIO.CHAPTER. Disengage the clips. MODEL . To remove the front door hinge. FRONT FENDER PANEL REMOVAL/INSTALLATION. 6.

TO. peel off the door screen partially.87–9.87–9. Remove the front door trim.9–12. Disconnect the negative battery cable.BACK. Raise the rear edge of the front door glass 80 mm {3. FROM.INDEX RANG. WITHOUT POWER WINDOW SYSTEM AND POWER DOOR LOCK SYSTEM B B A D E 6.CHAPTER.DRFT. 38–54} C 6. (Refer to TRIM. 60. Assemble in the reverse order of disassembly.80 {70–100.87–9.7 {90–130.INDEX DOOR FRONT DOOR DISASSEMBLY/ASSEMBLY 1.) 4. FRONT DOOR TRIM REMOVAL/INSTALLATION. To remove the inner handle.3–6. 6.1 in} from the fully lowered position. 38–54} 2. 3.1 {43–63. 18–26} F G 6.1 {43–63.REPAIR MANUAL PAGES. 79–112} H E A J G I 4. 60.80 {70–100.8–86.8–86. 5.9 {20–30.8–86. 2. MANUAL TO.7} D WITH POWER WINDOW SYSTEM AND POWER DOOR LOCK SYSTEM F 8.80 {70–100. 60. in·lbf} 1 2 3 4 5 6 7 Inner handle Door screen Front door glass Glass run channel Front glass guide Rear glass guide Front manual window regulator 8 9 10 11 12 13 14 Front power window regulator Outer handle Retainer Door key cylinder Front door lock (manual) Front door lock (power) Door lock knob CONTINUED S–6 . Disassemble in the order indicated in the table.0–2.7} J I N·m {kgf·cm.3–6. MODEL .7} H C 4.

) 3.22 in} 22—30 {2. Adjust the rear door. D—D SEC.) 3. REAR DOOR REMOVAL/INSTALLATION 1. Clearance a: 4.5—6. C—C 4 5 SEC. Remove in the order indicated in the table.25 in} g: 2.5 mm {0. To remove the checker.INDEX DOOR FRONT DOOR ADJUSTMENT 1. B—B (+) b (–) f a (+) c d e 1 2 3 Connector Checker pin Rear door hinge Rear door Checker SEC.0 mm {0.) CONTINUED S–7 . If not as specified.039 in} c: –2. MANUAL TO. 16—22} D D E E C C A A B B 8.23 in} b: –1.0—0. Measure the clearance between the door and the body.DRFT. A—A f g (–) SEC. (Refer to REAR DOOR ADJUSTMENT. ft·lbf} F F a (+) b (–) SEC.REPAIR MANUAL PAGES.5—1.11 in} h: 5. (Refer to FRONT DOOR REMOVAL/INSTALLATION.CHAPTER.) (Refer to DOOR LOCK STRIKER REMOVAL/INSTALLATION.16—0. Remove the door screen. (Refer to REAR DOOR DISASSEMBY/ASSEMBLY. 5.TO.7 N·m {90—130 kgf·cm.BACK.059—0.18—0. Disconnect the negative battery cable.5 mm {–0.0 mm {–0.9—12.5—8.INDEX RANG.33 in} e: 1. 79—112 in·lbf} N·m {kgf·m. remove the ashtray bracket.047 in} f: 3. 6.5 mm {0.078—0.14—0.5 mm {0. 2. E—E h SEC.019 in} d: 4.) 4.2—3.0—6. loosen the door hinge installation bolts or the door lock striker installation screws. (Refer to REAR DOOR DISASSEMBLY/ASSEMBLY.1. F—F 2. Tighten the bolts or the screws. MODEL . FROM. and move them to reposition the door.2 mm {0. Install in the reverse order of removal.7 mm {0.

) 4.1 {43—63.INDEX RANG.INDEX DOOR REAR DOOR DISASSEMBLY/ASSEMBLY 1. 2.7} 2. 60. Close the rear door glass completely.80 {70—100.80 {70—100. in·lbf} 1 2 3 4 5 6 Inner handle Door screen Ashtray bracket Glass hole lid Rear manual window regulator Rear power window regulator 7 8 9 10 11 12 Rear door glass + Removal Note Glass run channel Glass guide Door lock knob Rear door lock Outer handle CONTINUED S–8 .87—9.5 {25—36.8—86.7} E WITHOUT POWER WINDOW SYSTEM E 6.87—9.REPAIR MANUAL PAGES.CHAPTER.87—9. MANUAL TO. WITH POWER WINDOW SYSTEM 6. REAR DOOR TRIM REMOVAL/INSTALLATION. 60. 22—31} B B D A D C 4.7} C A N·m {kgf·cm.5—3.TO. 38—54} 6.8—86. (Refer to TRIM. Assemble in the reverse order of disassembly. 3.DRFT.80 {70—100. FROM. 5. MODEL . 60.BACK. Disassemble in the order indicated in the table.8—86. Remove the rear door trim.3—6. Disconnect the negative battery cable.

5 mm {0.TO.INDEX DOOR Rear Door Glass Removal Note D Draw out the rear door glass through the glass hole. REGULATOR HANDLE INSTALLATION 1.8–2. (Refer to REAR DOOR REMOVAL/INSTALLATION.7. DOOR LOCK STRIKER SCREW REAR DOOR 18–26 {1. Remove the door lock striker. MANUAL TO.DRFT. RAG C C (+) b (–) SEC. B–B (+) a a (+) b (–) c SEC. 14–19} REAR DOOR GLASS N·m {kgf·m.INDEX RANG. If not as specified. Measure the clearance between the door and the body.0 mm {–0. and move them to reposition the door. 2.) 3.22 in} DD A A E E B B 3.5—6. MODEL .BACK.5 mm {0. FROM. Remove the regulator handle. Remove the regulator handle clip using a rag as shown. FRONT CONTINUED S–9 . E–E 2. Tighten the bolts or screws.059—0. 2.25 in} b: –1. D–D SEC. REGULATOR HANDLE REMOVAL 1. DOOR LOCK STRIKER REMOVAL/INSTALLATION 1. Install in the reverse order of removal. SEC. Remove the screws. Set the door glass at the fully raised position and push the regulator handle on as shown. A–A (+) b (–) a b (–) SEC. ft·lbf} REAR DOOR ADJUSTMENT 1. loosen the door hinge installation bolts or the door lock striker installation CLIP screws.) (Refer to DOOR LOCK STRIKER REMOVAL/INSTALLATION.039 in} c: 5.CHAPTER. Clearance a: 3. Install the clip in the regulator handle. C–C CLIP a 2.14—0.REPAIR MANUAL PAGES.5—1.

Inspect for continuity between the power window main switch terminals using an ohmmeter. 3. (Refer to POWER WINDOW MAIN SWITCH REMOVAL/INSTALLATION. and disengage the hook.INDEX POWER WINDOW SYSTEM POWER WINDOW SYSTEM POWER WINDOW MAIN SWITCH REMOVAL/INSTALLATION 1. SWITCH PANEL Close Off Open ( ): R. Disengage the clip using a tape-wrapped flathead screwdriver.D.D. Pull the switch panel forward. Power-cut switch : Continuity Switch position ON OFF Terminal D A (H) B (I) H (A) I (B) POWER WINDOW MAIN SWITCH ( ): R. MODEL . 5. POWER WINDOW MAIN SWITCH INSPECTION Regular Cab.BACK. 3. Disconnect the negative battery cable. MANUAL TO.DRFT.TO. FROM. When inspecting the driver’s side.D.H.H. 2.INDEX RANG.H. Disconnect the power window main switch connector.) 2. When inspecting the passenger’s side. 4. Power window switch Driver’s side : Continuity SWITCH PANEL BODY CLIP BODY Switch position Manual close Off Auto open Manual open Terminal F D A (H) B (I) HOOK ( ): R. Passenger’s side : Continuity Switch position Terminal F D H (A) I (B) 4. Remove the screws to remove the power window main switch from the switch panel. Install in the reverse order of removal. SCREW 6. connect the battery positive voltage to terminal F and connect the ground to terminal D. Remove the switch panel. turn the power-cut switch to ON. Stretch Cab 1.REPAIR MANUAL PAGES. CONTINUED S–10 .CHAPTER.

Power-cut switch : Continuity Terminal Switch position ON OFF H L (D ) J (B ) D (L ) B (J) E C K I ( ): R. ∗ F D ∗ A B OPEN ( ): R.D.) or F (R. FROM.H.D. CONTINUED S–11 . MANUAL TO.BACK. 3. A H ( ): R.D. If not as specified. Double Cab 1.CHAPTER.REPAIR MANUAL PAGES. Passenger’s side : Continuity Switch position Close Off Open O en Terminal A (F) H D (L) B (J) J D B PASSENGER’S K I E C RIGH T ( ): R.D.H.H.H.H. connect the battery positive voltage to terminal A (L. Inspect for continuity between the power window main switch terminals using an ohmmeter. When inspecting the passenger’s side and rear.H.H.D. replace the power window main switch.TO.D. 4. Power window switch Driver’s side : Continuity Switch position Manual close Off Auto open Manual open Terminal A (F) H L (D) J (B) ( ): R.INDEX RANG.D.D. Rear right : Continuity Switch position Close Off O en Open Terminal A H E C 5. MODEL .DRFT.H.) and connect the ground to terminal H.H.INDEX POWER WINDOW SYSTEM Rear left F D : Continuity POWER-CUT SWITCH MANUAL OPEN CLOSE AUTO CIRCUIT AUTO OPEN OPEN Switch position Close Off O en Open Terminal A H K I MANUAL CLOSE I (B) H (A) PASSENGER’S SIDE CLOSE A (H) B (I) DRIVER’S SIDE H I ( ) : R. (Refer to POWER WINDOW MAIN SWITCH REMOVAL/INSTALLATION. turn the power-cut switch to ON. Remove the switch panel. When inspecting the driver’s side.D. L.) 2.

Pull the power window subswitch forward.DRFT. Disconnect the negative battery cable. 4.D.REPAIR MANUAL PAGES. Passenger’s side : Continuity Switch position Off Close Open O en Terminal A B D E F 5. (Refer to POWER WINDOW SUBSWITCH REMOVAL/INSTALLATION.TO.BACK. replace the power window main switch. MANUAL TO. MODEL .) 2. 2. and remove the power window subswitch. Remove the power window subswitch. 2. Rear 1. BODY CLIP POWER WINDOW SUBSWITCH CLOSE OPEN HOOK BODY E F D A B Rear : Continuity Switch position Close Terminal A B D E F 4. Install in the reverse order of removal. Disconnect the negative battery cable. Install in the reverse order of removal. 3. A F H HOOK J PASSENGER’S D B K L I J E C K I E H F C D A B POWER WINDOW SUBSWITCH 3.CHAPTER.H. If not as specified. 5. POWER WINDOW SUBSWITCH REMOVAL/INSTALLATION Passenger’s side 1. Disengage the clip using a tape-wrapped flathead screwdriver. Inspect for continuity between the power window subswitch terminals using an ohmmeter.INDEX RANG. flathead screwdriver between the switch and the rear door trim. and disengage the hook. FROM. POWER WINDOW SUBSWITCH INSPECTION 1. Disconnect the connector.INDEX POWER WINDOW SYSTEM R. Remove the hook by inserting a tape-wrapped. Off Open CONTINUED S–12 . Disconnect the power window subswitch connector.

FRONT POWER WINDOW REGULATOR REMOVAL/INSTALLATION 1. Assemble in the reverse order of disassembly.BACK. 2. Remove the door screen.0—4. 79—112} 3 D C Power Window Motor Disassembly Note D Make marks on the gear and base of the frame before disassembling the power window motor. 27—43 in·lbf} B A 8. 2. 3. 60. Remove the front glass guide and the rear glass guide.9—12. Install in the reverse order of removal. Disassemble in the order indicated in the table. Disconnect the negative battery cable. 1 2 3 4 Front power window regulator connector Bolt Nut Front power window regulator FRONT POWER WINDOW REGULATOR DISASSEMBLY/ASSEMBLY 1.87—9. CONTINUED S–13 .80 {70—100. Disconnect the negative battery cable.9 N·m {30—50 kgf·cm. FRONT DOOR DISASSEMBLY/ASSEMBLY. Remove in the order indicated in the table. MANUAL TO.) 4. 2. 2 Power window motor + Disassembly Note + Assembly Note Frame 3.REPAIR MANUAL PAGES. (Refer to DOOR. Raise the rear edge of the front door glass 80 mm {3.CHAPTER.8—86. MODEL . FROM. If not as specified. replace the power window subswitch.DRFT.) 4. REAR POWER WINDOW REGULATOR REMOVAL/INSTALLATION 1. in·lbf} Power Window Motor Assembly Note D Align the marks of the gear and the frame to install the power window motor.INDEX RANG.7 {90—130.TO. BASE MARK A B D C 6.7} GEAR N·m {kgf·cm. 3. (Refer to DOOR.INDEX POWER WINDOW SYSTEM F D B F CLOSE OPEN E A E D B A 3.1 in} from the fully lowered position. Remove in the order indicated in the table. Raise the rear door glass completely. Install in the reverse order of removal. 5. 1 Bolt 5. REAR DOOR DISASSEMBLY/ASSEMBLY.

3. 1 2 Bolt Power window motor + Disassembly Note + Assembly Note Frame 3 CONTINUED S–14 .8—86. MANUAL TO.8 N·m {31—49 kgf·cm.DRFT. FROM. Remove the power window motor.INDEX POWER WINDOW SYSTEM Power Window Motor Disassembly Note D Make marks on the gear and base of the frame before disassembling the power window motor. MODEL . Assemble in the reverse order of disassembly.80 N·m {70—100 kgf·cm. replace the power window motor. MARK A A BASE D C 6. 60.TO.87—9. Disassemble in the order indicated in the table.INDEX RANG.) 2. B+: Battery positive voltage Connection B+ A B UP 1 2 3 Rear power window regulator connector Bolt Rear power window regulator REAR POWER WINDOW REGULATOR DISASSEMBLY/ASSEMBLY 1.7 in·lbf} GEAR Power Window Motor Assembly Note D Align the marks of the gear and base of the frame to install the power window motor.CHAPTER. (Refer to FRONT POWER WINDOW REGULATOR DISASSEMBLY/ASSEMBLY.1—4. If not as specified. POWER WINDOW MOTOR INSPECTION 1. 27—42 in·lbf} GND B A DOWN Motor operation Up Down A B A B 3. Apply battery positive voltage to the power window motor terminals and inspect the operation of the power window motor.) (Refer to REAR POWER WINDOW REGULATOR DISASSEMBLY/ASSEMBLY. 2.BACK.REPAIR MANUAL PAGES.

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

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

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

BUMPER FUEL-FILLER LID AND OPENER FUEL-FILLER LID REMOVAL/INSTALLATION 1. Clearance a: 3.BACK.14—0.8—86.87—9.TO. 60. ft·lbf} 1 2 Front bumper Front bumper stay b A FRONT BUMPER DISASSEMBLY/ASSEMBLY 1. FROM. Tighten the fuel-filler lid installation bolts. Remove as indicated in the table. 2—3} 12345678 N·m {kgf·cm. Install in the reverse order of removal. 60.3 {2—4.INDEX FUEL-FILLER LID AND OPENER. 47—68} N·m {kgf·m.4—9.4—9.INDEX RANG. Disassemble in the order indicated in the table.8—86. 3.5.07 in} A a 6.7 in·lbf} 1 Fuel-filler lid FUEL-FILLER LID ADJUSTMENT 1.80 {70—100.8 {2—9. If not as specified.2—0.80 N·m {70—100 kgf·cm. 2.7} 0. Assemble in the reverse order of disassembly. Install in the reverse order of removal.80 N·m {70—100 kgf·cm. Remove in the order indicated in the table. MANUAL TO. MODEL . 63—93 {6.0 mm {–0.2—0.5—2.5—5. Measure the gap and height between the fuel-filler lid and the body.8—86. loosen the fuel-filler lid installation bolts and reposition the fuel-filler lid.01—0.5. in·lbf} 1 2 3 Front bumper side fascia Front bumper upper fascia Front bumper lower fascia CONTINUED S–19 .5 mm {0.7 in·lbf} 63—93 {6.21 in} b: –0. 47—68} 6. 2—7} SEC.87—9.DRFT. 6. 0. 2. BUMPER FRONT BUMPER REMOVAL/INSTALLATION 1.CHAPTER.87—9. 60.A–A 2. 2.REPAIR MANUAL PAGES.

0—11. Assemble in the reverse order of disassembly.80 N·m {70—100 kgf·cm. Remove the bolts.8—86.2—4. then remove the rear bumper. MODEL .9. 4. Install in the reverse order of removal. 12345678 CONTINUED S–20 .0—86. 2.0—86. Disconnect the negative battery cable. then remove the center bumper step.9 in·lbf} B N·m {kgf·m. FROM.3. 58. 3. 60.7 in·lbf} A B N·m {kgf·m.87—9. ft·lbf} 2. 1 2 3 4 5 6 Side bumper step + Removal Note Center bumper step + Removal Note Rear bumper fascia Rear bumper stay Rear bracket Set plate Side Bumper Step Removal Note 1.80 N·m {70—100 kgf·cm.87—9.78 N·m {3.6—2.0 kgf·cm.CHAPTER. Disengage clips B. Disassemble in the order indicated in the table.30—0. 12—16} N·m {kgf·m. MANUAL TO. 2. 6. ft·lbf} CLIP A 1 3 Rear bumper stay Rear bumper fascia Center Bumper Step Removal Note 1.7—6. 60. Remove in the order indicated in the table. ft·lbf} 0. Disconnect the rear fog light connector. 24—33} A B A A B BOLT 79—116 {8. REAR BUMPER DISASSEMBLY/ASSEMBLY With Step 1.TO. Remove the screws.INDEX BUMPER REAR BUMPER REMOVAL/INSTALLATION With Step 1. Disengage clips A using pliers. A A A A A SIDE BUMPER STEP A 79—116 {8. 3.0—11. Install in the reverse order of removal.9. 58.REPAIR MANUAL PAGES.0—8. Disengage clips A using pliers.7. 2.DRFT.0} 16—22 {1.INDEX RANG. 2. 2.BACK. Pull the side bumper step upward.8—86. then remove it. Without Step 1.7 in·lbf} 32—46 {3.0} REAR BUMPER 6.

then remove the cowl grille. A SCREW A A A SCREW A A A A CENTER BUMPER STEP CLIP B CLIP A A RADIATOR GRILLE A CLIP A A 2. MODEL . Remove the windshield wiper arm and blade. CONTINUED S–21 . Install in the reverse order of removal.REPAIR MANUAL PAGES. 3. WINDSHIELD GARNISH REMOVAL/INSTALLATION 1. Remove the screws.INDEX BUMPER.BACK.CHAPTER. (Refer to section T. Install in the reverse order of removal. SCREW COWL GRILLE WEATHERSTRIP 4. WIPER ARM AND BLADE REMOVAL/INSTALLATION. then disengage hook A from the cowl grille. EXTERIOR ATTACHMENT B SCREW A B A B SCREW A B EXTERIOR ATTACHMENT RADIATOR GRILLE REMOVAL/INSTALLATION 1. COWL GRILLE REMOVAL/INSTALLATION 1. Remove the screws. Remove the weatherstrip. Pull the radiator grille toward you. MANUAL TO.DRFT. then disengage clips A to remove the radiator grille. 2. WIPER AND WASHER.INDEX RANG.) 2.TO. Pull the windshield garnish upward. FROM.

Pull the side protector. then remove it.3 mm {0.INDEX RANG. SIDE PROTECTOR INSTALLATION 1.CHAPTER. MANUAL TO.19 in} e : 25.0—6.8—5. soften the double-sided adhesive tape using a hot air blower.0—8.19—0.8 mm {0.48 in} c : 10. MODEL .5 mm {1.55 in} d : 16.23 in} c : 13.5—17. Clearance a : 4. Remove the adhesive remaining on the side protector (if it will be reused) and the body using a razor knife.8—1. Always wear gloves when using a razor knife.65—0.INDEX EXTERIOR ATTACHMENT CENTER SIDE PROTECTOR (REGULAR CAB) d c SCREW a a e a c c WINDSHIELD GARNISH COWL GRILLE DOUBLE-SIDED ADHESIVE TAPE CENTER SIDE REAR SIDE PROTECTOR PROTECTOR (STRETCH CAB) d d d b c c a a A A HOOK c e c a c c e e a c a c a d ca d FRONT SIDE PROTECTOR b 1. Install in the reverse order of removal.0 mm {0. 3.0 mm {0. 2.22 in} b : 5. 1. Peel off the backing paper from the double-sided adhesive tape and attach the side protector onto the body as shown.51—0.TO.08—0.31 in} Regular Cab CENTER SIDE PROTECTOR FRONT SIDE PROTECTOR A A b a c REAR SIDE PROTECTOR f SEC.39 in} d : 2. Note D The side protector is installed with double-sided adhesive tape.66 in} e : 12.0 mm {0. 2.49—0.0 mm {0—0.REPAIR MANUAL PAGES. Clearance a : 0—3. Pry the side protector end 20—30 mm {0.0—5. If the side protector is difficult to remove.52 in} f : 6.3—13. FROM. Remove any grease or dirt from the adhesion surface of the side protector (if it will be reused) and the body.0 mm {0.0 mm {0.20—0.0 mm {0.0—14.98 in} 4. SIDE PROTECTOR REMOVAL Warning D Using a razor knife with bare hands can cause injury.1 in} using a flathead screwdriver or a razor knife.24—0.BACK.0 mm {0. A—A CONTINUED S–22 . Attach double-sided adhesive tape to the side protector as shown (if it will be reused).DRFT.11 in} b : 37. A—A Stretch Cab CENTER SIDE PROTECTOR FRONT SIDE PROTECTOR A A b a d REAR SIDE PROTECTOR f SEC.

INDEX RANG.CHAPTER. Disconnect the rods from the tailgate lock. etc. Remove the handle. Remove the bolts. Loosen the bolts. 3. OVER FENDER FASTENER REAR A A A A A A A OVER FENDER SCREW CLIP BOLT STRIKER SCREW FASTENER 4. BOLT LATCH GUIDE ROD LATCH 6. 2. 7. then remove the over fender.INDEX EXTERIOR ATTACHMENT Double Cab NUT REAR SIDE PROTECTOR f e b TAILGATE LOCK FRONT SIDE PROTECTOR A A SEC. FRONT CLIP A A A A A A 5. 37 ft·lbf} or more with a roller. Disengage clips A of the over fender using a fastener remover.DRFT. Move the striker forward and rearward until the tailgate will lock properly. Assemble in the reverse order of disassembly. 2.TO. CONTINUED S–23 . then remove the latch guide.0 kgf·m. After the correct adjustment is made. Remove the tailgate lock. After installing the side protector to the body. Remove the fasteners. A—A ROD 5.BACK. 3. 3. tighten the bolts securely. 2. Remove the cover. MANUAL TO. Remove the screws. FROM. Remove the nuts attaching the tailgate lock. OVER FENDER REMOVAL/INSTALLATION 1. apply pressure of 50 N·m {5. TAILGATE DISASSEMBLY/ASSEMBLY 1.REPAIR MANUAL PAGES. TAILGATE ADJUSTMENT 1. 4. latch and rod. Install in the reverse order of removal. MODEL .

) WINDSHIELD SIDE MOLDING REMOVAL D Remove the windshield side molding from the windshield. 2.INDEX EXTERIOR ATTACHMENT. (Refer to WINDOW GLASS.) FRONT BELTLINE MOLDING REMOVAL/INSTALLATION 1.) 3. Remove the screws and bolts.) (Refer to OUTSIDE MIRROR. CONTINUED S–24 . A CLIP A A BELTLINE MOLDING A 5. MOLDING ROPE HOOK REMOVAL/INSTALLATION 1. FRONT BELTLINE MOLDING BOLT 2.DRFT. MODEL . POWER OUTSIDE MIRROR REMOVAL/INSTALLATION. Lower the front door glass fully. WINDSHIELD REMOVAL.CHAPTER. Install in the reverse order of removal.REPAIR MANUAL PAGES. WINDSHIELD REMOVAL. (Refer to WINDOW GLASS.TO. WINDSHIELD INSTALLATION. (Refer to OUTSIDE MIRROR. HOOK 4. MANUAL TO. (Refer to WINDOW GLASS. then remove the rope hook. (Refer to WINDOW GLASS. Install in the reverse order of removal.INDEX RANG.) WINDSHIELD UPPER MOLDING INSTALLATION D Install the windshield upper molding to the windshield.BACK. Remove the manual outside mirror or the power outside mirror. MANUAL OUTSIDE MIRROR REMOVAL/INSTALLATION. then remove clips A. WINDSHIELD INSTALLATION.) ROPE HOOK SCREW ROPE HOOK WINDSHIELD SIDE MOLDING INSTALLATION D Install the windshield side molding to the windshield. Pull the front beltline molding upward. FROM. Pull the rear end of the front beltline molding to disengage the hook. MOLDING WINDSHIELD UPPER MOLDING REMOVAL D Remove the windshield upper molding from the windshield.

(Refer to TRIM. 2. Remove the inner garnish. Remove the inner garnish. 3. 2.INDEX RANG. Disconnect the negative battery cable. 2. FROM. Remove the screws. 4. FRONT DOOR TRIM REMOVAL/INSTALLATION. FRONT DOOR TRIM REMOVAL/INSTALLATION. Install in the reverse order of removal. CONTINUED S–25 .INDEX MOLDING. BELTLINE MOLDING CLIP A A A A 4. (Refer to TRIM. Pull the rear beltline molding upward.) 4.TO. Pull the rear end of the rear beltline molding to disengage the hook. 7. (Refer to TRIM. A ROOF MOLDING ROOF MOLDING CLIP BODY A A A POWER OUTSIDE MIRROR REMOVAL/INSTALLATION 1. Lower the rear door glass fully. 3. MANUAL OUTSIDE MIRROR SCREW HOOK 3. Pull the rear edge of roof molding upward. 6. POWER OUTSIDE MIRROR SCREW POWER OUTSIDE MIRROR CONNECTOR 8. Apply battery positive voltage to the power outside mirror and inspect the operation of the power outside mirror. Remove the front door trim. FRONT DOOR TRIM REMOVAL/INSTALLATION. REAR BELTLINE MOLDING OUTSIDE MIRROR MANUAL OUTSIDE MIRROR REMOVAL/INSTALLATION 1. 5. then disengage clips A. 2. Install in the reverse order of removal.) 3. Partially peel off the door screen. Install in the reverse order of removal. Remove the front door trim. Remove the front door trim. Disconnect the power outside mirror connector. 2. Install in the reverse order of removal. 5.CHAPTER. 6. POWER OUTSIDE MIRROR INSPECTION 1.BACK. Remove the inner garnish. Remove the manual outside mirror. Remove the screws.) 4. MODEL .REPAIR MANUAL PAGES.DRFT. Partially peel off the door screen. then remove clips A. Disconnect the negative battery cable. ROOF MOLDING REMOVAL/INSTALLATION 1. Remove the power outside mirror. OUTSIDE MIRROR REAR BELTLINE MOLDING REMOVAL/INSTALLATION 1. Disconnect the power outside mirror connector. MANUAL TO. 5.

then remove it.INDEX OUTSIDE MIRROR B+: Battery positive voltage Connection B+ A C C D GND C A D C Mirror operation Up Down Left Right LH Left C A D : Continuity Switch position Up Down Terminal I L A D C B K Right Up DOWN UP Down * 123456567 M LEFT RH Left Right RIGHT M 1. Disconnect the power outside mirror switch connector. Inspect for continuity between the power outside mirror switch terminals using an ohmmeter. replace the power outside mirror. 7. Remove the power outside mirror switch. Install in the reverse order of removal. Remove the fuse block cover. FROM. Push the power outside mirror switch out. 3.TO.CHAPTER.) 2. 4. CONTINUED S–26 . 5. POWER OUTSIDE MIRROR SWITCH REMOVAL/INSTALLATION 1. If not as specified.BACK. Disconnect the negative battery cable. 6. MANUAL TO.INDEX RANG. If not as specified. 2. MODEL .REPAIR MANUAL PAGES. replace the power outside mirror switch.DRFT. Remove the fuse block installation screws. Insert your hand into the hole for the fuse block. (Refer to POWER OUTSIDE MIRROR SWITCH REMOVAL/INSTALLATION. and press the hooks of the power outside mirror switch. POWER OUTSIDE MIRROR SWITCH INSPECTION 1. and push the fuse block into the dashboard. POWER OUTSIDE MIRROR SWITCH POWER OUTSIDE MIRROR SWITCH CONNECTOR 3.

Turn the ignition switch to ON position. Install in the reverse order of removal. CONTINUED S–27 . Remove in the order indicated in the table. Double Cab 1. If not as specified. 2. replace the rear window defroster switch. 2. HOOK 2.TO. Regular Cab. Remove the meter hood. Turn the rear window defroster switch on.0—3. MODEL . Press the hooks of the rear window defroster switch and push the switch out. Remove the rear window defroster switch. 18—34} REAR WINDOW DEFROSTER SWITCH METER HOOD 4.) Stretch Cab. Install in the reverse order of removal.BACK. FROM. MANUAL TO. Caution D Directly touching the rear window defroster filament with the lead of the circuit tester will damage it. REAR WINDOW DEFROSTER REARVIEW MIRROR REARVIEW MIRROR REMOVAL/INSTALLATION Regular Cab REAR WINDOW DEFROSTER REAR WINDOW DEFROSTER SWITCH REMOVAL/INSTALLATION 1. (Refer to section T. Disconnect the negative battery cable.9 {20—40.REPAIR MANUAL PAGES.INDEX RANG.INDEX REARVIEW MIRROR. FILAMENT INSPECTION 1. 3. INTERIOR LIGHT REMOVAL/INSTALLATION.DRFT. Wrap aluminum foil around the end of the lead and test the filament by touching it with the foil. 2. in·lbf} 1 2 3 Cover Screw Rearview mirror D A : : C D A B C B 3. Inspect for continuity between the rear window defroster switch terminals using an ohmmeter. REAR WINDOW DEFROSTER SWITCH INSPECTION 1. 2. INTERIOR LIGHTING SYSTEM.CHAPTER. Note D The rearview mirror is attached to the interior light. : Continuity : Bulb Switch position ON OFF Terminal A B C D N·m {kgf·cm.

REPAIR MANUAL PAGES. MODEL .INDEX RANG. Connect the positive ()) lead of the voltmeter to the positive side of each filament and the negative (*) lead to ground. 12 V Approx. Gradually. Disconnect the rear window defroster relay connector. 3. If the voltage is not as specified or it changes rapidly. 5. 2. CONTINUED S–28 . MANUAL TO. ALUMINUM FOIL LEAD OF THE CIRCUIT TESTER PUSH FILAMENT 1. Attach tape above and below the damaged section of the filament. REAR WINDOW DEFROSTER RELAY (2) NEGATIVE SIDE (1) POSITIVE SIDE REAR WINDOW DEFROSTER RELAY CONNECTOR 4. Use white gasoline to clean around the damaged section of the filament. 4. : Continuity B+: Battery positive voltage Step 1 2 B) GND Terminal A B C D 3. the filament is faulty. FILAMENT REPAIR 1.BACK. Using a small brush or marking pen. carefully remove the tape without disturbing the repaired area. Use a hot air blower heated to 150°C {302°F} for 30 minutes or let the paint set for 24 hours at 25°C {77°F} to allow it to dry completely. Slide the rear window defroster relay upward. Remove the rear window defroster relay. Verify that the voltage decreases accordingly.TO. repair the filament with silver paint or equivalent. FROM. Repair the filament. Inspect for continuity between the rear window defroster relay terminals using an ohmmeter. 2. After approximately 2—3 minutes.) 2. REAR WINDOW DEFROSTER RELAY INSPECTION 1. If not as specified. It may cause other malfunctions if it is used before the paint is dry. Measurement place (1) (2) Voltage (Reference value) Approx. 0 V REAR WINDOW DEFROSTER RELAY REMOVAL/INSTALLATION 1.INDEX REAR WINDOW DEFROSTER Caution D Do not use the rear window defroster until the paint is completely dry.DRFT.CHAPTER. BROKEN FILAMENT TAPE D A C D SECTION TO BE REPAIRED A B C B 3. then remove it. Install in the reverse order of removal. slide the positive ()) lead from the positive side to the negative side and measure the voltage. (Refer to REAR WINDOW DEFROSTER RELAY REMOVAL/INSTALLATION. Disconnect the negative battery cable. replace the rear window defroster relay. 3. 2.

Note D The windshield upper molding and windshield side molding are replacement parts. Remove the windshield. Pull through the sealant around the edge of the glass. Cut the lip of the windshield upper molding using a razor knife.BACK. 2. CENTER DAM R SPACER R 8. Always wear gloves when using a piano wire. Make a hole through the sealant from the inside of the vehicle using an awl. 4.DRFT. Remove the spacer and the dam from the glass. 1.INDEX RANG. Remove the spacers from the body. 2. Remove the cowl grille.REPAIR MANUAL PAGES. Remove the windshield. Working with another person. use a piano wire and follow the procedures under “Reusing Windshield”. the body and the dashboard. Warning D Using a razor knife with bare hands can cause injury. Wind each end of the wire around a bar. 3. Remove the spacers from the body. PROTECTIVE TAPE LIP Not Reusing Windshield Warning D Using a piano wire with bare hands can cause injury. PROTECTIVE TAPE 49 0305 870A WINDSHIELD UPPER MOLDING R SEALANT WINDSHIELD DAM HEADLINER PROTECTIVE TAPE 3. 4. COWL GRILLE REMOVAL/INSTALLATION. R WINDSHIELD UPPER MOLDING Reusing Windshield 1. Note D Use the entire length of piano wire to prevent it from breaking when cutting through the sealant. 6.) 2.INDEX WINDOW GLASS WINDOW GLASS WINDSHIELD REMOVAL 1. 7. FROM. Use a tool like that shown in the figure. saw through the sealant around the edge of the glass. Pass the SST (piano wire) through the hole. Apply protective tape to the headliner. 49 0305 870A 5. Always wear gloves when using a razor knife. being careful not to damage the body. 3. MANUAL TO. and insert the blade into the sealant. Remove the windshield upper molding and the windshield side molding from the windshield.TO. CONTINUED S–29 .CHAPTER. Note D For the areas of the sealant that are difficult to cut. MODEL . (Refer to EXTERIOR ATTACHMENT.

30} CENTER BODY MARKING GLASS MARK SPACER mm {in} 13. 2. Install the windshield side molding from the upper part towards the lower part. Align the center mark on the windshield upper molding with the glass mark.DRFT. MODEL .BACK. Caution D Keep the area free of dirt and grease.5 {0. Align the upper edge of the windshield side molding with the glass mark.5 mm {0. WINDSHIELD UPPER MOLDING MARK 7. CONTINUED S–30 . 12.08 in} layer. Caution D To prevent the sealant from cracking or the glass from being pushed out by air pressure if a door is cl