Ford Escape F1A3!10!06C - 2

MECHANICAL [L3]
1 No.2 engine mount through bolt 5 No.3 engine mount bracket

2 Engine mount member, No.2 engine mount rubber (See 01-10A-27 Engine Mount Member, No.2 Engine
(See 01-10A-27 Engine Mount Member, No.2 Engine Mount Rubber Removal Note.)
Mount Rubber Removal Note.) (See 01-10A-27 Engine Mount Member, No.2 Engine
(See 01-10A-27 Engine Mount Member, No.2 Engine Mount Rubber Removal Note.)
Mount Rubber Removal Note.) 6 No.4 engine mount through bolt
3 No.1 engine mount through bolt 7 No.4 engine mount bracket
4 No.1 engine mount rubber (See 01-10A-27 Engine Mount Member, No.2 Engine
8
Mount Rubber Removal Note.)
Engine, transaxle
01
Engine Mount Member, No.2 Engine Mount Rubber Removal Note

1. Install the SST using the following procedure.
Caution
MAIN FRAME
• Refer to the SST instruction manual for
the basic handing procedure.
REAR SHAFT
SIDE BAR
FRONT SHAFT
FRONT FOOT No.1

(ADAPTER FOR FRONT SHAFT)
FRONT FOOT No.2

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(1) Install the right rear shaft of the SST to the

bolt of the right shock absorber as shown in
49 C017 5A0
the figure.
(2) Install the left rear shaft of the SST to the bolt
of the left shock absorber. (Identical position
to the right side)
FRONT SIDE
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01-10A–27
MECHANICAL [L3]
(3) Install the left/right front shaft of the SST with
front foot No.2 to the bolt as shown in the RH
49 C017 5A0
figure.
(4) Adjust the positions of the SST side bars so
that they are the same height (left and right)
and horizontal.
(5) Make sure each joint is securely tightened.
LH
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2. Support the engine using the SST.

49 C017 5A0
Note
• The SST (49 E017 5A0) can be used in
place of the SST (49 C017 5A0).
3. Remove the engine mount member and No.2

engine mount rubber.
49 L017 5A0
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No.3 Engine Mount Bracket Removal Note

1. Secure the engine and transaxle using an engine ENGINE, TRANSAXLE
jack and attachment.
ATTACHMENT
ENGINE JACK
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2. Remove the SST.

49 C017 5A0
49 L017 5A0
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01-10A–28
MECHANICAL [L3]
No.4 Engine Mount Rubber Installation Note
1. Secure the engine and transaxle using an engine ENGINE, TRANSAXLE
jack and attachment.
2. Install the No.4 engine mount bracket to the
transaxle and temporarily tighten the bolts and
nuts. ATTACHMENT
3. Temporarily tighten the No.4 engine mount rubber
and bracket through bolt.
Caution
01
• Make sure that the through bolt is
completely seated. ENGINE JACK
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4. Tighten the new No.4 engine mount bracket bolts,

nuts, and through bolt in the order as shown in the 2 4
figure.
Caution
• After tightening nut (2), retighten nut (1).
1
Tightening torque
Nut (1), (2): 66.6—93.1 N·m {6.80—9.49 kgf·m,
49.2—68.6 ft·lbf}
Bolt (3): 66.6—93.1 N·m {6.80—9.49 kgf·m,
3
49.2—68.6 ft·lbf}
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Bolt (4): 85.3—116.6 N·m {8.70—11.8 kgf·m,
63.0—85.9 ft·lbf}
No.3 Engine Mount Bracket Installation Note

1. Tighten the No.3 engine mount bracket
installation stud bolts.
Tightening torque
7.0—13.0 N·m {71.4—132 kgf·cm, 62.0—115
in·lbf}
2. Install the No.3 engine mount bracket and

temporarily tighten.
NO.3 ENGINE MOUNT BRACKET
INSTALLATION STUD BOLT
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3. Tighten the No.3 engine mount bracket bolt and

nut in the order shown in figure.
1
Tightening torque
74.5—104.9 N·m {7.60—10.6 kgf·m, 55.0—
77.3 ft·lbf} 2
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01-10A–29
MECHANICAL [L3]
Caution
MAIN FRAME
REAR SHAFT
SIDE BAR
FRONT SHAFT
FRONT FOOT No.1

FRONT FOOT No.2

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49 C017 5A0
the figure.
to the right side)
FRONT SIDE
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49 C017 5A0
figure.
and horizontal.
LH
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01-10A–30
MECHANICAL [L3]
49 C017 5A0
Note
6. Remove the engine jack.
49 L017 5A0
01
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No.1 Engine Mount Rubber Installation Note
Caution
• After removing the SST (49 E017 5A0), tighten the No.1 engine mount rubber properly.
1. Install the No.1 engine mount rubber to the crossmember and temporarily tighten.
2. Tighten the No.1 engine mount through bolt.
Tightening torque
85.3—116.3 N·m {8.70—11.8 kgf·m, 63.0—85.7 ft·lbf}
Engine Mount Member, No.2 Engine Mount Rubber Installation Note
Caution
• Temporarily tighten the No.2 engine mount through bolt, install the engine mount member, and
then properly tighten the through bolt.
1. Tighten the engine mount member bolts and nut.
Tightening torque
66.6—93.1 N·m
{6.80—9.49 kgf·m, 49.2—68.6 ft·lbf}
2. Remove the SST.

49 C017 5A0
3. Properly tighten the No.1 engine mount rubber
bolts and nut.
Tightening torque
66.6—93.1 N·m
{6.80—9.49 kgf·m, 49.2—68.6 ft·lbf}
4. Tighten the No.2 engine mount through bolt.

49 L017 5A0
Tightening torque
85.3—116.3 N·m {8.70—11.8 kgf·m, 63.0—85.7
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ft·lbf}
End Of Sie
ENGINE DISASSEMBLY/ASSEMBLY[L3]
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1. Disconnect the engine and transaxle. (See 05-17A-20 AUTOMATIC TRANSAXLE AND TRANSFER
REMOVAL/INSTALLATION[GF4AX-EL].)
2. Remove the intake-air system. (See 01-13A-5 INTAKE-AIR SYSTEM REMOVAL/INSTALLATION[L3].)
3. Remove the exhaust system. (See 01-15A-2 EXHAUST SYSTEM REMOVAL/INSTALLATION[L3].)
4. Remove the generator.
5. Remove the CKP sensor. (See 01-40A-37 CRANKSHAFT POSITION (CKP) SENSOR REMOVAL/
INSTALLATION[L3].)
6. Assemble in the reverse order of disassembly.
End Of Sie
WM: VARIABLE VALVE TIMING ACTUATOR
01-10A–31
MECHANICAL [L3]
VARIABLE VALVE TIMING ACTUATOR INSPECTION[L3]
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Caution
• Variable valve timing actuator can not be disassembled it is a precision unit.
1. Disconnect the negative battery cable.

2. Remove the ignition coils. (See 01-18A-2 IGNITION COIL REMOVAL/INSTALLATION[L3])
3. Remove the spark plugs. (See 01-18A-3 SPARK PLUG REMOVAL/INSTALLATION[L3].)
4. Disconnect the oil control valve connector.
5. Remove the ventilation hose.
6. Remove the cylinder head cover.
7. Confirm that notch of the rotor and bump of the cover at the variable valve timing actuator are aligned and fitted.
• If the notch and the bump are not aligned, turn the crankshaft clockwise two rotations. Verify that the bump
and the notch are aligned.
• If the bump and notch are still not aligned, replace the variable valve timing actuator.
• If, when turning the crankshaft, there is a hitting noise from the variable valve timing actuator each time the
cam passes the fully lifted position, it means that the actuator is not secured. Replace the actuator.
8. Install the cylinder head cover.
9. Install the ventilation hose.
10. Connect the oil control valve connector.
11. Install the spark plugs.
12. Install the ignition coils. NOTCH
End Of Sie
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VARIABLE VALVE TIMING ACTUATOR REMOVAL/INSTALLATION[L3]

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Caution
• Variable valve timing actuator can not be disassembled because it is a precision unit.
Note
• Intake camshaft sprocket is integrated with the variable valve timing actuator and cannot be
disassembled.
1. Follow the valve clearance adjustment procedure from 1 to 20 and remove the intake camshaft and variable
valve timing actuator as a single unit. (See 01-10A-5 VALVE CLEARANCE ADJUSTMENT[L3].)
2. Remove the variable valve timing actuator.
(1) Mark the camshaft and variable valve timing
actuator as shown in the figure to make sure
they are installed in their original position.
(2) Secure the camshaft in a vise.
(3) Loosen the variable valve timing actuator
tightening bolt.
MARK
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01-10A–32
MECHANICAL [L3]
3. Install a new washer.
4. Install the variable valve timing actuator.
(1) Secure the camshaft in a vise.
(2) Align the marks of the camshaft and variable
valve timing actuator.
Caution
• When the variable valve timing actuator R
is replaced with a new one, mark it in the
same location as the old one.
01
(3) Tighten the variable valve timing actuator
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tightening bolt.
Tightening torque
69—75 N·m {7.1—7.6 kgf·m, 51—55 ft·lbf}
5. Follow the valve clearance adjustment procedure from 24 to 48 and install the intake camshaft and variable
valve timing actuator. (See 01-10A-5 VALVE CLEARANCE ADJUSTMENT[L3].)
End Of Sie
OIL CONTROL VALVE (OCV) REMOVAL/INSTALLATION[L3]
WM: OIL CONTROL VALVE (OCV)
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2. Remove the ignition coils. (See 01-18A-2 IGNITION COIL REMOVAL/INSTALLATION[L3])
3. Remove the oil control valve (OCV) connector.
4. Remove the ventilation hose.
5. Remove the cylinder head cover.
6. Remove in the order indicated in the table.
7. Install in the reverse order of removal.
1 8.0—11.5 N·m
1 Oil control valve (OCV) {82—117 kgf·cm,
71—101 in·lbf}
End Of Sie
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OIL CONTROL VALVE (OCV) INSPECTION[L3]

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Coil Resistance Inspection
2. Disconnect the oil control valve connector.
3. Measure the resistance between terminals A and B using an ohmmeter.
• If not as specified, replace the oil control valve.
Oil control valve resistance

6.9—7.9 ohms [20°C {68°F}]
4. Connect the oil control valve connector.

OIL CONTROL VALVE (OCV)
A B
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01-10A–33
MECHANICAL [L3]
Spool Valve Operation Inspection
2. Remove the oil control valve.
3. Verify that the spool valve in the oil control valve is in the maximum valve timing retard position as indicated in
the figure.
• If not as specified, replace the oil control valve.
4. Verify that the battery is fully charged.
• If not as specified, recharge the battery.
5. Apply battery positive voltage between the oil
control valve terminals and verify that the spool
valve operates and moves to the maximum valve
timing advance position.
• If not as specified, replace the oil control
valve.
SPOOL VALVE
Note
• When applying battery positive voltage
between the oil control valve terminals, the
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connection can be either of the following:
— Positive battery cable to terminal A,
negative battery cable to terminal B
— Positive battery cable to terminal B, negative battery cable to terminal A
6. Stop applying battery positive voltage and verify

that the spool valve returns to the maximum valve
timing retard position. VALVE TIMING VALVE TIMING
RETARD
• If not as specified, replace the oil control ADVANCE
valve.
End Of Sie
WM: ENGINE COMPLETE
SPOOL VALVE
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ENGINE TUNE-UP[L3]
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Engine Tune-up Preparation
1. Turn off the electrical loads.
2. Warm up the engine as follows.
(1) Start the engine.
(2) Maintain the engine speed approx. 3,000 rpm until the cooling fans start to operate.
(3) Release the accelerator pedal.
(4) Wait until the cooling fans stop.
3. Connect the IDS/PDS to the DLC-2.
DLC-2
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01-10A–34
MECHANICAL [L3]
Ignition Timing Inspection
Note
• Ignition timing is not adjustable.
• Ignition timing verification requires IDS/PDS.
1. Verify that the ignition timing (IDS/PDS: SPARKADV PID) is within the specification using IDS/PDS.
Ignition timing
Approx. BTDC 8°
01
2. Verify that ignition timing advances when the engine speed increases gradually.
Idle Speed Inspection
Note
• Idle speed is not adjustable.
• Idle speed verification requires IDS/PDS.
1. Verify that the idle speed (IDS/PDS: RPM PID) is within the specification using IDS/PDS.
Idle speed (N position)

No load: 650—750 rpm
Electrical loads on*1: 650—750 rpm
P/S operation: 650—750 rpm
A/C operation: 650—750 rpm
*1 : Blower motor is operating at high speed. Headlight switch is turned on. Rear window defroster switch is turned
on. Cooling fans are operating.
Idle Mixture Inspection

1. Verify that the idle speed and ignition timing are within the specification. (See 01-10A-35 Idle Speed
Inspection.) (See 01-10A-35 Ignition Timing Inspection.)
2. Insert an exhaust gas analyzer to the tailpipe.
3. Verify that the CO and HC concentrations are within the regulation.
Idle mixture
HC concentration: Within the regulation
CO concentration: Within the regulation
End Of Sie
01-10A–35
MECHANICAL [AJ (3.0L Duratec)]
01-10B MECHANICAL [AJ (3.0L Duratec)]

ENGINE LOCATION INDEX HYDRAULIC LASH ADJUSTER (HLA)
[AJ (3.0L Duratec)] . . . . . . . . . . . . . . . . 01-10B–2 REMOVAL/INSTALLATION
DRIVE BELT INSPECTION [AJ (3.0L Duratec)] . . . . . . . . . . . . . . . . 01-10B–27
[AJ (3.0L Duratec)] . . . . . . . . . . . . . . . . 01-10B–3 CRANKSHAFT PULLEY
DRIVE BELT REMOVAL/INSTALLATION REMOVAL/INSTALLATION
[AJ (3.0L Duratec)] . . . . . . . . . . . . . . . . 01-10B–4 [AJ (3.0L Duratec)] . . . . . . . . . . . . . . . . 01-10B–30
DRIVE BELT AUTO TENSIONER CYLINDER HEAD (LH) 01
INSPECTION[AJ (3.0L Duratec)] . . . . . 01-10B–6 REMOVAL/INSTALLATION
COMPRESSION INSPECTION [AJ (3.0L Duratec)] . . . . . . . . . . . . . . . . 01-10B–32
[AJ (3.0L Duratec)] . . . . . . . . . . . . . . . . 01-10B–6 CYLINDER HEAD (RH)
ENGINE FRONT COVER REMOVAL/INSTALLATION
REMOVAL/INSTALLATION [AJ (3.0L Duratec)] . . . . . . . . . . . . . . . . 01-10B–34
[AJ (3.0L Duratec)] . . . . . . . . . . . . . . . . 01-10B–8 FRONT OIL SEAL
CYLINDER HEAD COVER (LH) REMOVAL/INSTALLATION
[AJ (3.0L Duratec)] . . . . . . . . . . . . . . . . 01-10B–10 REAR OIL SEAL
CYLINDER HEAD COVER (RH) REMOVAL/INSTALLATION
[AJ (3.0L Duratec)] . . . . . . . . . . . . . . . . 01-10B–12 No.3 ENGINE MOUNT
TIMING CHAIN REMOVAL/INSTALLATION REMOVAL/INSTALLATION
CAMSHAFT (LH) ENGINE REMOVAL
[AJ (3.0L Duratec)] . . . . . . . . . . . . . . . . 01-10B–22 ENGINE INSTALLATION
CAMSHAFT (RH) [AJ (3.0L Duratec)] . . . . . . . . . . . . . . . . 01-10B–50
REMOVAL/INSTALLATION ENGINE DISASSEMBLY/ASSEMBLY
ENGINE TUNE-UP
[AJ (3.0L Duratec)] . . . . . . . . . . . . . . . . 01-10B–61
End of Toc
WM: ENGINE COMPLETE
01-10B–1
ENGINE LOCATION INDEX[AJ (3.0L Duratec)]
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5
6
4 7
8
12 10
11
14 15
13
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1 Front drive belt 3 Engine

(See 01-10B-3 DRIVE BELT INSPECTION[AJ (3.0L (See 01-10B-6 COMPRESSION INSPECTION[AJ
Duratec)].) (3.0L Duratec)].)
(See 01-10B-4 DRIVE BELT REMOVAL/ (See 01-10B-40 ENGINE REMOVAL[AJ (3.0L
INSTALLATION[AJ (3.0L Duratec)].) Duratec)].)
(See 01-10B-6 DRIVE BELT AUTO TENSIONER (See 01-10B-50 ENGINE INSTALLATION[AJ (3.0L
INSPECTION[AJ (3.0L Duratec)].) Duratec)].)
2 Water pump drive belt (See 01-10B-60 ENGINE DISASSEMBLY/
(See 01-10B-3 DRIVE BELT INSPECTION[AJ (3.0L ASSEMBLY[AJ (3.0L Duratec)].)
Duratec)].) 4 Engine front cover
(See 01-10B-4 DRIVE BELT REMOVAL/ (See 01-10B-8 ENGINE FRONT COVER
INSTALLATION[AJ (3.0L Duratec)].) REMOVAL/INSTALLATION[AJ (3.0L Duratec)].)
5 Cylinder head cover (LH)
(See 01-10B-32 CYLINDER HEAD (LH) REMOVAL/
INSTALLATION[AJ (3.0L Duratec)].)
6 Cylinder head cover (RH)
(See 01-10B-34 CYLINDER HEAD (RH)
REMOVAL/INSTALLATION[AJ (3.0L Duratec)].)
01-10B–2
7 Camshaft (LH) 11 Crankshaft pulley
(See 01-10B-22 CAMSHAFT (LH) REMOVAL/ (See 01-10B-30 CRANKSHAFT PULLEY
8 Camshaft (RH) 12 Front oil seal
(See 01-10B-25 CAMSHAFT (RH) REMOVAL/ (See 01-10B-36 FRONT OIL SEAL REMOVAL/
INSTALLATION[AJ (3.0L Duratec)].) INSTALLATION[AJ (3.0L Duratec)].)
9 Timing chain 13 Cylinder head (LH)
(See 01-10B-15 TIMING CHAIN REMOVAL/ (See 01-10B-32 CYLINDER HEAD (LH) REMOVAL/
10
Hydraulic lash adjuster (HLA) 14
Cylinder head (RH)
01
(See 01-10B-27 HYDRAULIC LASH ADJUSTER (See 01-10B-34 CYLINDER HEAD (RH)
(HLA) REMOVAL/INSTALLATION[AJ (3.0L REMOVAL/INSTALLATION[AJ (3.0L Duratec)].)
Duratec)].) 15 Rear oil seal
(See 01-10B-37 REAR OIL SEAL REMOVAL/
End Of Sie
DRIVE BELT INSPECTION[AJ (3.0L Duratec)]
WM: DRIVE BELT
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Front Drive Belt
Note
• Drive belt deflection/tension inspection is not necessary because of the use of the front drive belt auto
tensioner.
1. Verify that the drive belt auto tensioner indicator

NORMAL
mark does not exceed the limit.
• If it exceeds the limit, replace the drive belt. LIMIT
(See 01-10B-4 DRIVE BELT REMOVAL/
INSTALLATION[AJ (3.0L Duratec)].) AUTO TENSIONER
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MALFUNCTION
LIMIT
AUTO TENSIONER
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Water Pump Drive Belt
Note
• Water pump drive belt deflection/tension inspection is not necessary because of the use of the stretched-
type water pump drive belt.
• Replace the water pump drive belt if visual inspection indicates any damage or abnormal sound from the
water pump drive.
End Of Sie
01-10B–3
DRIVE BELT REMOVAL/INSTALLATION[AJ (3.0L Duratec)]
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Front Drive Belt Removal/Installation
1. Remove the front wheel and tire. (RH)
2. Remove the bolts, nut and front lower splash
shield. (RH)
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3. Turn the drive belt auto tensioner clockwise to AUTO

release tension to the drive belt. TENSIONER
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Water Pump Drive Belt Removal/Installation

Removal
1. Remove the plug hole plate.
2. Remove the front wheel and tire. (RH)
3. Remove the bolts, nut and front lower splash
shield. (RH) 8.9—12.7 N·m
{90—130 kgf·cm, 67.8—112 in·lbf}
Caution
• To prevent the belt from snapping back,
always hold down the belt while cutting
it. Also, keep your face away from the
belt.
• The belt is not reusable.
6.9—9.8 N·m
{70—100 kgf·cm, 61—86 in·lbf}
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4. Hold down the belt while cutting as shown in the

figure.
CUTTING POINT
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01-10B–4
Installation
Note
• It is acceptable to use a tie wrap with a releasable lock.
1. Secure the water pump drive pulley and the belt

using a tie wrap.
2. Rotate the crankshaft verifying that the belt
engages properly. 01
Crankshaft rotating angle (reference)
Approx. 110°
Caution
• If the belt slips while rotating the
crankshaft, verify that the belt engages
properly by rotating the crankshaft
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further.
3. Verify that the belt is installed securely in the pulley groove.
Caution
• To prevent damage to the belt when removing the tie wrap, cut the tie wrap at the pulley side using
a nipper or scissors.
4. Remove the tie wrap.
CUTTING POINT
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5. Install the bolts, nut and front lower splash shield.

8.9—12.7 N·m
(RH)
{90—130 kgf·cm, 67.8—112 in·lbf}
6. Install the front wheel and tire. (RH)
7. Install the plug hole plate.
Tightening torque
5.2—7.2 N·m {54—73 kgf·cm, 47—63 in·lbf}
End Of Sie
WM: DRIVE BELT AUTO TENSIONER
6.9—9.8 N·m
{70—100 kgf·cm, 61—86 in·lbf}
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01-10B–5
DRIVE BELT AUTO TENSIONER INSPECTION[AJ (3.0L Duratec)]
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Front Drive Belt Auto Tensioner
1. Remove the front drive belt. (See 01-10B-4 DRIVE BELT REMOVAL/INSTALLATION[AJ (3.0L Duratec)].)
2. Verify that the drive belt auto tensioner moves smoothly in the operational direction.
• If it does not move smoothly, replace the drive belt auto tensioner.
3. Rotate the drive belt auto tensioner pulley by AUTO
hand and verify that it rotates smoothly. TENSIONER
• If it does not rotate smoothly, replace the drive
belt auto tensioner. OPERATIONAL
DIRECTION
4. Install the front drive belt. (See 01-10B-4 DRIVE
BELT REMOVAL/INSTALLATION[AJ (3.0L
Duratec)].)
End Of Sie
WM: ENGINE COMPLETE
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COMPRESSION INSPECTION[AJ (3.0L Duratec)]

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Warning
• Hot engines can cause severe burns. Be careful not to burn yourself during removal/installation of
each component.
1. Verify that the battery is fully charged. (See 01-17B-2 BATTERY REMOVAL/INSTALLATION[AJ (3.0L
Duratec)].)
2. Warm up the engine.
Warning
• Fuel vapor is hazardous. It can very easily ignite, causing serious injury and damage. Always keep
sparks and flames away from fuel.
• Fuel line spills and leakage from the pressurized fuel system are dangerous. Fuel can also irritate
skin and eyes. To prevent this, before performing the fuel pump unit removal/installation, always
complete the Fuel Leakage Inspection, and remove the fuel pump relay. (See 01-14B-4 BEFORE
SERVICE PRECAUTION[AJ (3.0L Duratec)].)
3. Stop the engine and allow approx. 10 min for the exhaust system to cool down.
4. Disconnect the ignition coil connector. (See 01-18B-2 IGNITION COIL REMOVAL/INSTALLATION[AJ (3.0L
Duratec)].)
5. Remove all the spark plugs. (See 01-18B-3 SPARK PLUG REMOVAL/INSTALLATION[AJ (3.0L Duratec)].)
6. Measure the compression pressure using the following procedure.
(1) Connect the compression gauge into the
spark plug hole.
(2) Crank the engine a minimum of five
compression strokes and record the highest
reading.
Note
• Note the approximate number of
compression strokes required to obtain the
highest reading.
(3) Repeat the test on each cylinder, cranking the

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engine approximately the same number of
compression strokes.
(4) The indicated compression pressures are considered within specification if the lowest reading cylinder is
within 75 percent of the highest reading. Refer to the compression pressure limit chart.
• If the compression in one or more cylinders is low or the compression difference between cylinders
exceeds the maximum, pour a small amount of clean engine oil into the cylinder and recheck the
compression.
— If the pressure increases by adding the engine oil, the piston ring or the cylinder surface is worn, or
they are damaged. Perform overhaul servicing.
— If the pressure does not increase, valve seizure, valve attachment failure, or pressure leaking from
the cylinder head gasket might be occurring. Perform overhaul servicing. If the compression stays
low, a valve may be struck or improperly seated and timing chain inspection is required.
01-10B–6
Compression Pressure Limit Chart
kPa {kgf/cm2, psi}
Maximum Minimum Maximum Minimum Maximum Minimum Maximum Minimum
pressure pressure pressure pressure pressure pressure pressure pressure
924 696 1131 848 1338 1000 1544 1158
{9.41, 134} {7.10, 101} {11.52, 164} {8.65, 123} {13.63, 194} {10.20, 146} {15.73, 224} {11.81, 168}
938 703 1145 855 1351 1014 1558 1165
{9.56, 136} {7.17, 102} {11.67, 166} {8.72, 124} {13.77, 196} {10.34, 147} {15.88, 226} {11.88, 169}
952 717 1158 869 1365 1020 1572 1179 01
{9.70, 138} {7.31, 104} {11.80, 168} {8.86, 126} {13.91, 198} {10.40, 148} {16.02, 228} {12.02, 171}
965 724 1172 876 1379 1034 1586 1186
{9.83, 140} {7.38, 106} {11.94, 170} {8.93, 127} {14.05, 200} {10.54, 150} {16.16, 230} {12.09, 172}
979 738 1186 889 1303 1041 1600 1200
{9.97, 142} {7.53, 107} {12.08, 172} {9.07, 129} {13.28, 202} {10.62, 151} {16.30, 232} {12.24, 174}
933 745 1200 903 1407 1055 1055 1207
{9.51, 144} {7.60, 109} {12.23, 174} {9.21, 131} {14.34, 204} {10.76, 153} {10.75, 153} {12.31, 175}
1007 758 1214 910 1420 1062 1627 1220
{10.26, 146} {7.73, 110} {12.37, 176} {9.28, 132} {14.47, 206} {10.83, 154} {16.58, 154} {12.44, 177}
1020 765 1227 917 1434 1075 1641 1227
{10.39, 148} {7.80, 111} {12.50, 178} {9.35, 133} {14.61, 208} {10.96, 156} {16.72, 238} {12.51, 178}
1034 779 1241 931 1448 1083 1655 1241
{10.54, 150} {7.94, 113} {12.65, 180} {9.49, 135} {14.76, 210} {10.04, 157} {16.87, 240} {12.65, 180}
1048 786 1255 936 1462 1089 1669 1248
{10.68, 152} {8.02, 114} {12.79, 182} {9.54, 136} {14.90, 212} {11.10, 158} {17.01, 242} {12.73, 181}
1062 793 1269 952 1476 1103 1682 1262
{10.82, 154} {8.09, 115} {12.93, 184} {9.70, 138} {15.04, 214} {11.25, 160} {17.14, 244} {12.87, 183}
1076 807 1282 965 1489 1117 1696 1269
{10.96, 156} {8.23, 117,} {13.06, 186} {9.84, 140} {15.17, 216} {11.39, 162} {17.28, 246} {12.94, 184}
1089 814 1296 972 1503 1124 1710 1202
{11.10, 158} {8.30, 118} {13.21, 188} {9.91, 141} {15.32, 218} {11.46, 163} {17.43, 248} {12.26, 186}
1103 827 1310 979 1517 1138 1724 1289
{11.24, 160} {8.43, 120} {13.35, 190} {9.98, 142} {15.46, 220} {11.60, 165} {17.57, 250} {13.14, 187}
1110 834 1324 993 1631 1145
{11.31, 161} {8.50, 121} {13.49, 192} {10.2, 144} {16.62, 222} {11.67, 166}
Note
• After measuring the compression pressure of all cylinders, if maximum reading is 1,351 kPa {13.77 kgf/
cm2, 196 psi} and minimum reading is 1,069 kPa {10.89 kgf/cm2, 227 psi} the engine condition is within
the specification and compression is normal.
Standard
1,480 kPa {15.10 kgf/cm2, 215 psi} [210 rpm]
7. Install the fuel pump relay.

8. Install the spark plugs. (See 01-18B-3 SPARK PLUG REMOVAL/INSTALLATION[AJ (3.0L Duratec)].)
9. Install the ignition coils. (See 01-18B-2 IGNITION COIL REMOVAL/INSTALLATION[AJ (3.0L Duratec)].)
End Of Sie
WM: ENGINE FRONT COVER
01-10B–7
ENGINE FRONT COVER REMOVAL/INSTALLATION[AJ (3.0L Duratec)]
id0110a3802800
2. Remove the oil pan. (See 01-11B-5 OIL PAN REMOVAL/INSTALLATION[AJ (3.0L Duratec)].)
3. Remove the front oil seal. (See 01-10B-36 FRONT OIL SEAL REMOVAL/INSTALLATION[AJ (3.0L Duratec)].)
4. Remove the generator. (See 01-17B-4 GENERATOR REMOVAL/INSTALLATION[AJ (3.0L Duratec)].)
5. Remove the LH and RH cylinder head cover. (See 01-10B-10 CYLINDER HEAD COVER (LH) REMOVAL/
INSTALLATION[AJ (3.0L Duratec)].) (See 01-10B-12 CYLINDER HEAD COVER (RH) REMOVAL/
6. Remove the No.3 engine mount. (See 01-10B-38 No.3 ENGINE MOUNT REMOVAL/INSTALLATION[AJ (3.0L
Duratec)].)
7. Remove the power steering oil pump and bracket with the power steering pressure line connected, and fix the
power steering oil pump using a rope to prevent it from falling. (See 06-14-38 POWER STEERING OIL PUMP
6 R
20—30 {2.1—3.0, 15—22}
20—30 {2.1—3.0, 15—22}
8—12 N·m 2 SEALANT
{82—122 kgf·cm,
71—106 in·lbf}
10—14 N·m
8—12 N·m
{102—142 kgf·cm,
{82—122 kgf·cm, 71—106 in·lbf}
89—123 in·lbf}
4 3
20—30 {2.1—3.0, 15—22} 5
1
N·m {kgf·m, ft·lbf}
atraaw00000994
1 Drive belt auto tensioner 5 Engine front cover

2 CMP sensor connector (See01-10B-9 Engine Front Cover Removal Note.)
(See01-10B-9 Engine Front Cover Installation Note.)
3 CKP sensor connector
6 Gasket
4 Front cover bracket
01-10B–8
Engine Front Cover Removal Note
1. Remove the engine front cover bolts and studs in
the order shown.
3
2 6
7
1
4
01
5
8
10 9
14
16 15
11 12
13
atraaw00002935
Engine Front Cover Installation Note
Note
• The engine front cover must be installed and the bolts tightened within six minutes of applying the sealant.
1. Apply a 6 mm {0.24 in} diameter dot of Silicone

Gasket to the cylinder block, lower cylinder block,
and cylinder head mating surfaces.
6 mm {0.24 in}
atraaw00000015
01-10B–9
2. Position the cover and install the studs and bolts 20—30 N·m
in the sequence shown. {2.1—3.0 kgf·m, 15—22 ft·lbf}
Note 15
• Fasteners No. 1, 3, 4, 8, 10, 11, 14, 15 and 14
10 11
16 are studs.
16
End Of Sie 13
WM: CYLINDER HEAD COVER
12
9
7 8
3
1 2
6 5
4
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CYLINDER HEAD COVER (LH) REMOVAL/INSTALLATION[AJ (3.0L Duratec)]

id0110a3802600
Removal
2. Disconnect the crankcase ventilation tube from the cylinder head cover.
3. Remove the ignition coils (LH).
(1) Disconnect the connector. 1
(2) Remove the bolt. 2
(3) Remove the ignition coil.
3
atraaw00000362
4. Disconnect the wiring harness from the cylinder

head cover studs.
atraaw00000363
01-10B–10
5. Remove the engine hanger.
01
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6. Remove the cylinder head cover bolts and studs 11

in the order shown. 4 2 8
9
6
13 12
7
3 1
5 10
atraaw00000639
Installation
1. Position a new gasket on the cylinder head cover.
2. Apply a 8 mm {0.32 in} dot of Silicone Gasket 8 mm {0.32 in}
Sealant to the front cover to cylinder head joints. SEALANT
8 mm {0.32 in}
Note
• The cylinder head cover must be installed
and the bolts tightened within six minutes of
applying the sealant.
8 mm {0.32 in}
8 mm {0.32 in} SEALANT
atraaw00000640
3. Position the cylinder head cover and install the

studs and the bolts in the sequence shown.
3
10 12 6
5
8
1 2
7
11 13
9 4
8—12 N·m
{82—122 kgf·cm, 71—106 in·lbf}
atraaw00000641
01-10B–11
4. Position the engine hanger and install the bolt.
100—125 N·m
{10.2—12.7 kgf·m, 73.8—92.1 ft·lbf}
atraaw00000368
5. Connect the wiring harness to the cylinder head

cover studs.
atraaw00000363
6. Install the ignition coils (LH).

(1) Position the ignition coil. 6.0—8.0 N·m 3
(2) Install the bolt. 2 {62—81 kgf·cm, 54—70 in·lbf}
(3) Connect the connector.
7. Connect the crankcase ventilation tube to the
cylinder head cover.
8. Install the plug hole plate.
Tightening torque
5.2—7.2 N·m {54—73 kgf·cm, 47—63 in·lbf}
1
End Of Sie atraaw00000995
CYLINDER HEAD COVER (RH) REMOVAL/INSTALLATION[AJ (3.0L Duratec)]

id0110a3802700
Removal
1. Remove the dynamic chamber. (See 01-13B-6 DYNAMIC CHAMBER REMOVAL/INSTALLATION[AJ (3.0L
Duratec)].)
2. Remove the ignition coil (RH).
(1) Disconnect the three electrical connectors. 1
2
(2) Remove the three bolts.
(3) Remove the ignition coil.
3
atraaw00000370
01-10B–12
3. Remove the wiring harness nuts and disconnect
the HO2S connectors.
01
atraaw00000371
4. Disconnect the condenser.

5. Disconnect the PCV hose from the cylinder head
cover.
atraaw00000372
6. Remove the cylinder head cover bolts and studs

in the order shown. 6 4 2 11
8
1
13 12
10
5 7 3 9
atraaw00000730
Installation
1. Install a new cylinder head cover gasket.
2. Apply a 8 mm {0.32 in} dot of silicone sealant to 8 mm {0.32 in}
the front cover to cylinder head joints. SEALANT
Note
• The cylinder head cover must be installed
and the bolts tightened within six minutes of
applying the sealant.
SEALANT
8 mm {0.32 in}
atraaw00000731
01-10B–13
3. Position the cylinder head cover and install the
bolt and the studs in the sequence shown.
4. Connect the PCV hose to the cylinder head cover.
8 10 12 3
6
13
1 2
4
7 11 5
9
8—12 N·m
{82—122 kgf·cm, 71—106 in·lbf}
atraaw00000732
5. Connect the condenser.
atraaw00000372
6. Connect the HO2S connectors and wiring

harness to the RH cylinder head cover stud.
atraaw00000371
7. Install the ignition coils (RH).

(1) Position the ignition coils. 6.0—8.0 N·m 3
(2) Install the three bolts. 2 {62—81 kgf·cm, 54—70 in·lbf}
(3) Connect the connector.
8. Install the dynamic chamber. (See 01-13B-6
DYNAMIC CHAMBER REMOVAL/
End Of Sie
WM: TIMING CHAIN
1
atraaw00000996
01-10B–14
TIMING CHAIN REMOVAL/INSTALLATION[AJ (3.0L Duratec)]
id0110a3801000
Warning
• Fuel line spills and leakage are dangerous. Fuel can ignite and cause serious injuries or death and
damage. Fuel can also irritate skin and eyes. To prevent this, always complete the “Fuel Line
Safety Procedure”. (See 01-14B-4 BEFORE SERVICE PRECAUTION[AJ (3.0L Duratec)].)
01
Removal
1. Remove the engine front cover. (See 01-10B-8 ENGINE FRONT COVER REMOVAL/INSTALLATION[AJ (3.0L
Duratec)].)
2. Remove the ignition CKP sensor pulse wheel.
aesffw00000510
3. Install the crankshaft pulley lock bolt.
Note
• The RH side is shown, however, the LH side
is the same.
atraaw00000610
4. Remove the LH and RH spark plugs.
atraaw00000611
01-10B–15
5. Rotate the crankshaft clockwise to position the
crankshaft keyway to the 11 o’clock position and
position the camshafts in the correct position. 36.70°
This will position the number one cylinder at top 97.77°
7.43°
dead center (TDC).
63.49°
Caution
• Do not rotate the crankshaft
counterclockwise. The timing chains may
bind, causing engine damage.
0 0
atraaw00000612
6. Rotate the crankshaft clockwise 120° to the 3

o’clock position to locate the RH camshafts in the
neutral position.
atraaw00000613
7. Place alignment marks on the timing chain

corresponding to each of the alignment marks on
the timing sprocket.
3 O'CLOCK
POSITION
atraaw00000614
8. Remove the RH timing chain and tensioner arm.

(1) Remove the bolt.
(2) Remove the tensioner.
(3) Remove the tensioner arm.
3
2
1
atraaw00000615
01-10B–16
9. Remove the bolts, RH timing chain guide and the
timing chain.
01
atraaw00000616
10. Rotate the crankshaft clockwise 1and 2/3 turns to

position the crankshaft keyway to the 11 o’clock
position. This will position the LH camshafts to the
neutral position.
atraaw00000617
11. Place alignment marks on the timing chain

corresponding to each of the alignment marks on
the timing sprocket.
11 O'CLOCK
POSITION
atraaw00000618
12. Remove the LH timing chain and tensioner arm.

(1) Remove the bolt. 3
(2) Remove the tensioner.
(3) Remove the tensioner arm.
2
atraaw00000619
13. Remove the LH timing chain and timing chain

guide.
atraaw00000620
01-10B–17
14. Remove the crankshaft pulley lock bolt and the
crankshaft sprockets.
atraaw00000621
Installation
1. Install the crankshaft sprockets.
Note
is the same.
atraaw00000622
2. Position the chain tensioner in a soft-jawed vise.
Note
is the same.
atraaw00000623
3. Hold the chain tensioner ratchet lock mechanism

away from the ratchet stem with a small pick.
Note
• During tensioner compression, do not
release the ratchet stem until the tensioner
piston is fully set to the bottom of its bore.
Otherwise damage to the ratchet stem will
result.
4. Slowly compress the timing chain tensioner.

atraaw00000624
01-10B–18
5. Retain the tensioner piston with a 1.5 mm {0.059
in} wire or paper clip.
01
atraaw00000625
6. If timing marks on the timing chains are not

evident, use a permanent-type marker to mark on
the LH and RH timing chains.
(1) Mark any link to use as the crankshaft timing
mark. 1
(2) Count 29 links from the crankshaft timing
mark and mark as the exhaust cam sprocket 2
timing mark. 3
(3) Continue counting to 42 and mark the link as
the intake sprocket timing mark.
atraaw00000626
7. Position the guide and install the bolts.

8. Position the mark on the intake camshaft to 9
o’clock position.
20—30 N·m {2.1—3.0

kgf·m, 15—22 ft·lbf}
atraaw00002409
9. Position the mark on the exhaust camshaft to 12 ,

9 O CLOCK INTAKE SIDE ,
o’clock position. 12 O CLOCK
EXHAUST
SIDE
atraaw00000628
10. Install the LH timing chain.

(1) Position number one link on the crankshaft 3 2
timing mark.
(2) Count 29 links from the number one link, and
position on the exhaust cam sprocket.
(3) Continue counting to 42 and position the link
on the intake sprocket timing mark.
atraaw00000629
01-10B–19
11. Install the LH timing chain and tensioner arm.
(1) Install the tensioner arm. 1
(2) Position the tensioner.
(3) Install the bolt.
20—30 N·m {2.1—3.0
kgf·m, 15—22 ft·lbf} 3
atraaw00000630
12. Install the crankshaft pulley lock bolt and rotate

the crankshaft keyway to the 3 o’clock position.
13. Position the mark on the exhaust camshaft to 12
o'clock position.
atraaw00000613
14. Position the mark on the intake camshaft to 3 INTAKE SIDE ,

, 3 O CLOCK
o'clock position. 12 O CLOCK
EXHAUST
SIDE
atraaw00000631
15. Position the RH timing chain and chain guide and

install the bolts.
(1) Align the marks on the timing chain with the
marks on the camshaft and crankshaft
sprockets.
20—30 N·m {2.1—3.0

atraaw00000632
01-10B–20
16. Install the RH timing chain tensioner and
tensioner arm.
(1) Install the tensioner arm.
(2) Position the tensioner.
17. Remove the LH and RH timing chain tensioner 1
piston retaining wires or paper clip. 2
3
20—30 N·m
{2.1—3.0 kgf·m, 01
15—22 ft·lbf}
atraaw00000633
18. Remove the crankshaft pulley lock bolt.
atraaw00000634
19. Install the CKP sensor pulse wheel with the

colored code area pointed towards the front of the
vehicle.
COLOR CODE AREA
aesffw00000511
20. Install the LH and RH spark plugs. (RH shown.

LH similar.)
21. Install the engine front cover. (See 01-10B-8
ENGINE FRONT COVER REMOVAL/
22. Start the engine and:
• Inspect for the engine oil, engine coolant,
transaxle oil and fuel leakage.
• Verify the ignition timing, idle speed and idle
mixture.
9—20 N·m
End Of Sie
WM: CAMSHAFT
{91—204 kgf·cm, 79—177 in·lbf}
atraaw00000635
01-10B–21
CAMSHAFT (LH) REMOVAL/INSTALLATION[AJ (3.0L Duratec)]
id0110a3803500
Removal
1. Remove the water pump drive belt. (See 01-10B-4 DRIVE BELT REMOVAL/INSTALLATION[AJ (3.0L
Duratec)].)
2. Remove the timing chain. (See 01-10B-15 TIMING CHAIN REMOVAL/INSTALLATION[AJ (3.0L Duratec)].)
3. Replace SST [303-457 (49 UN30 3457)] with SST
[303-009 (49 UN30 3009)] component A. 303-009
(49 UN30 3009)
COMPONENT A
303-457
(49 UN30 3457)
atraaw00000024
4. Using SSTs, remove the water pump drive pulley.

303-009
5. Cut the oil seal lip using a razor knife.
(49 UN30 3009)
Note
• In order to assure correct sealing do not 303-457
scratch the camshaft. (49 UN30 3457)
303-456
(49 UN30 3456)
atraaw00000025
6. Using a flathead screwdriver, remove the

camshaft oil seal.
CAMSHAFT OIL SEAL
atraaw00000026
7. Remove the bolts and the camshaft oil seal

retainer.
Caution
• Remove the camshaft bearing thrust
caps No. 1L and 6L first. Do not loosen
any of the other bolts until the thrust
caps are removed, or damage to the
thrust caps may occur.
Note
• Cylinder head and the camshaft bearing
atraaw00000027
caps are numbered to make sure they are
assembled in their original position. When
removed, keep the bearing caps with the cylinder head from where they were removed together. Do not
mix the caps.
8. Loosen bolts in several passes.
Note
• Do not remove bolts completely.
01-10B–22
9. Remove the camshaft (LH) thrust caps 1L and 6L.
4 01
atraaw00000028
10. Loosen the remaining bolts 7—8 turns in the

indicated sequence to allow the camshaft (LH) to 15 16 13 14 17 18
rise.
7 8 5 6 9 10 11 12
atraaw00000029
11. Remove the camshafts.
atraaw00000997
Installation
1. Lubricate the camshafts with engine oil, and carefully position the camshafts into the cylinder head.
2. Position the mark on the intake camshaft to 9 o’clock position.
3. Position the mark on the exhaust camshaft to 12 , INTAKE SIDE
o’clock position. 9 O CLOCK ,
12 O CLOCK
Caution EXHAUST
SIDE
• Be sure the camshaft caps are installed
in their original positions.
atraaw00000155
01-10B–23
4. Lubricate the bearing surfaces of the camshaft
bearing caps with engine oil. Install the camshaft
bearing caps and loosely install the bolts.
Caution
• Do not install the camshaft thrust caps
until all of the camshaft caps have been
installed, or damage to the camshaft
atraaw00000998

thrust caps with engine oil. Install the camshaft
thrust caps and loosely install the bolts.
Note
• After adjusting the camshaft end play using
the thrust caps 1L and 6L, tighten the other
bearing caps.
atraaw00000032
6. Tighten the bearing caps evenly in the order

shown in several passes.
7. Install the timing chain. (See 01-10B-15 TIMING
CHAIN REMOVAL/INSTALLATION[AJ (3.0L 2 1 4 3 6 5
Duratec)].) 8
7
17
18
10 9 12 11 14 13 16 15
8—12 N·m
{82—122 kgf·cm, 71—106 in·lbf}
atraaw00000033
8. Install the camshaft oil seal retainer.

8—12 N·m
{82—122 kgf·cm, 71—106 in·lbf}
Note
• Lubricate the camshaft oil seal with engine
oil.
atraaw00000037
01-10B–24
9. Using the SSTs, install a new camshaft oil seal.
303-464 211-185
Press-in amount (49 UN30 3464) (49 UN21 1185)
2.5—3.0 mm {0.10—0.11 in}
303-463 01
(49 UN30 3463)
atraaw00000598
10. Using the SST, install the water pump drive

pulley. 211-185
11. Install the water pump belt. (See 01-10B-4 DRIVE (49 UN21 1185)
Duratec)].)
End Of Sie
atraaw00000036
CAMSHAFT (RH) REMOVAL/INSTALLATION[AJ (3.0L Duratec)]

id0110a3803600
Removal
1. Remove the timing chain. (See 01-10B-15 TIMING CHAIN REMOVAL/INSTALLATION[AJ (3.0L Duratec)].)
Caution
• Remove the camshaft bearing thrust caps No. 1R and 5R first. Do not loosen any of the other bolts
until the thrust caps are removed, or damage to the thrust caps may occur.
Note
• Cylinder head and the camshaft bearing caps are numbered to make sure they are assembled in their
original position. When removed, keep the bearing caps with the cylinder head from where they were
removed together. Do not mix the caps.
2. Loosen the bolts in several passes.
Note
• Do not remove bolts completely.
3. Remove the camshaft (RH) thrust caps 1R and

5R.
1
atraaw00003297
01-10B–25
4. Loosen the remaining bolts 7—8 turns in the
indicated sequence to allow the camshaft (RH) to 7 8 5 6 9 10
rise.
13 14 12 11 15 16
atraaw00003298
5. Remove the camshafts.
atraaw00000046
Installation
1. Lubricate camshafts with engine oil, and carefully position the camshafts into the cylinder head.
2. Position the mark on the exhaust camshaft to 12 o'clock position.
3. Position the mark on the intake camshaft to 3 INTAKE SIDE ,
, 3 O CLOCK
o'clock position. 12 O CLOCK
EXHAUST
Caution SIDE
• Be sure camshaft caps are installed in
the original positions.
atraaw00000157

bearing caps with engine oil, and install the
camshaft bearing caps and loosely install the
bolts.
Caution
• Do not install the camshaft thrust caps
until all of the camshaft caps have been
installed, or damage to the camshaft
atraaw00000048
01-10B–26
thrust caps with engine oil. Install the camshaft
thrust caps and loosely install the bolts.
Note
• After adjusting the camshaft end play using
the thrust caps 1R and 5R, tighten the other
bearing caps.
01
atraaw00000049
6. Tighten the bearing caps evenly in the order

shown in several passes.
7. Install the timing chain. (See 01-10B-15 TIMING
10 9 12 11 14 13
CHAIN REMOVAL/INSTALLATION[AJ (3.0L
Duratec)].) 16
End Of Sie
WM: HYDRAULIC LASH ADJUSTER (HLA)
15
2 1 4 3 6 5
8—12 N·m
{82—122 kgf·cm, 71—106 in·lbf}
atraaw00003299
HYDRAULIC LASH ADJUSTER (HLA) REMOVAL/INSTALLATION[AJ (3.0L Duratec)]

id0110a3804100
2. Remove the splash shield. (RH)
Duratec)].)
6. Remove the ignition coil. (See 01-18B-2 IGNITION COIL REMOVAL/INSTALLATION[AJ (3.0L Duratec)].)
7. Remove the water pump drive belt and water pump drive pulley. (See 01-10B-4 DRIVE BELT REMOVAL/
INSTALLATION[AJ (3.0L Duratec)]) (See 01-10B-22 CAMSHAFT (LH) REMOVAL/INSTALLATION[AJ (3.0L
Duratec)])
8. Remove the camshaft oil seal and the camshaft oil seal retainer. (See 01-10B-22 CAMSHAFT (LH) REMOVAL/
INSTALLATION[AJ (3.0L Duratec)])
01-10B–27
Note
• Inspect the hydraulic lash adjusters for scoring marks and uneven wear in the bore. Install new lash
adjusters if necessary.
8—12 N·m {82—122
kgf·cm, 71—106 in·lbf} 8—12 N·m {82—122
5.0—7.0 N·m {51—71 kgf·cm, 71—106 in·lbf}
kgf·cm, 45—61 in·lbf} 3
5
4
8—12 N·m {82—122
R kgf·cm, 71—106 in·lbf}
8 R
9 13 12
11
8—12 N·m {82—122 10
kgf·cm, 71—106 in·lbf}
SEALANT
1
SEALANT
2
100—125
{10.2—12.7,
73.8—92.1}
7 SST
SEALANT
6 R 8—12 N·m {82—122
120 {12.2, 88.5} —360°, +47—53
{4.8—5.4, 35—39} + (85°—95°)
atraaw00000069
1 Engine hanger Crankshaft pulley

7 (See 01-10B-30 CRANKSHAFT PULLEY
2 Oil level gauge tube
Cylinder head cover (LH)
Camshaft cap bolt (RH)
3 (See 01-10B-10 CYLINDER HEAD COVER (LH)
(See 01-10B-29 Camshaft Cap (RH) Removal
8 Note.)
4 Condenser (See 01-10B-30 Camshaft Cap (RH) Installation
Cylinder head cover (RH) Note.)
5 (See 01-10B-12 CYLINDER HEAD COVER (RH) Rocker arm (RH)
REMOVAL/INSTALLATION[AJ (3.0L Duratec)].) 9
(See 01-10B-29 Rocker Arm (RH) Removal Note.)
Crankshaft pulley lock bolt HLA (RH)
6 (See 01-10B-30 CRANKSHAFT PULLEY 10 (See 01-10B-30 Hydraulic Lash Adjuster (HLA)
REMOVAL/INSTALLATION[AJ (3.0L Duratec)].) Installation Note.)
01-10B–28
Camshaft cap bolt (LH) Rocker arm (LH)
12
(See 01-10B-29 Camshaft Caps (LH) Removal (See 01-10B-29 Rocker Arm (LH) Removal Note.)
11 Note.) HLA (LH)
(See 01-10B-30 Camshaft Caps (LH) Installation 13 (See 01-10B-30 Hydraulic Lash Adjuster (HLA)
Note.) Installation Note.)
Camshaft Cap (RH) Removal Note
Note
01
• Only loosen the camshaft cap so that the camshaft rises slightly.
1. Perform Steps 5 and 6 in TIMING CHAIN REMOVAL/INSTALLATION, Removal. (See 01-10B-15 TIMING
CHAIN REMOVAL/INSTALLATION[AJ (3.0L Duratec)].)
2. Perform Steps from 2 to 4 in CAMSHAFT (RH) REMOVAL/INSTALLATION, Removal. (See 01-10B-25
CAMSHAFT (RH) REMOVAL/INSTALLATION[AJ (3.0L Duratec)].)
Rocker Arm (RH) Removal Note
Caution
• If the rocker arm and HLA are to be reused, mark their positions to make sure they are assembled
in their original position.
• Take care not to let the rocker arm slip into the timing chain cover when removing the rocker arm
from engine front.
1. Lift the camshaft slightly.

2. Remove the 12 rocker arms.
ROCKER ARM
atraaw00000070
Camshaft Caps (LH) Removal Note
Note
• Only loosen the camshaft cap so that the camshaft rises slightly.
1. Perform Step 10 in TIMING CHAIN REMOVAL/INSTALLATION, Removal. (See 01-10B-15 TIMING CHAIN
2. Perform Steps from 8 to 10 in CAMSHAFT (LH) REMOVAL/INSTALLATION, Removal. (See 01-10B-22
CAMSHAFT (LH) REMOVAL/INSTALLATION[AJ (3.0L Duratec)].)
Rocker Arm (LH) Removal Note
Caution
• If the rocker arm and HLA are to be reused, mark their positions to make sure they are assembled
in the original position.
• Take care not to let the rocker arm slip into the timing chain cover when removing the rocker arm
from engine front.
1. Lift the camshaft slightly.
01-10B–29
2. Remove the 12 rocker arms.
ROCKER ARM
atraaw00000070
Camshaft Caps (LH) Installation Note

1. Perform Step from 2 to 6 in CAMSHAFT (LH) REMOVAL/INSTALLATION, Installation. (See 01-10B-22
CAMSHAFT (LH) REMOVAL/INSTALLATION[AJ (3.0L Duratec)].)
Camshaft Cap (RH) Installation Note

1. Perform Steps from 12 to 14 in TIMING CHAIN REMOVAL/INSTALLATION, Installation. (See 01-10B-15
TIMING CHAIN REMOVAL/INSTALLATION[AJ (3.0L Duratec)].)
2. Perform Step from 4 to 6 in CAMSHAFT (RH) REMOVAL/INSTALLATION, Installation. (See 01-10B-25
CAMSHAFT (RH) REMOVAL/INSTALLATION[AJ (3.0L Duratec)].)
Hydraulic Lash Adjuster (HLA) Installation Note

1. Lubricate HLA with engine oil.
End Of Sie
CRANKSHAFT PULLEY REMOVAL/INSTALLATION[AJ (3.0L Duratec)]
WM: CRANKSHAFT PULLEY
id0110a3803000
Removal
2. Secure the crankshaft pulley using the SST and
49 E011 1A1 49 H012 006 or M8 x1.25
loosen the crankshaft pulley lock bolt. length 40 mm {1.5 in}
49 S120 710
atraaw00000342
3. Remove the crankshaft pulley bolt and washer.
atraaw00000343
01-10B–30
4. Using the SST, remove the crankshaft pulley.
303-009
(49 UN30 3009)
01
M8x1.25
length 45mm {1.8 in}
atraaw00000344
Installation
Note
• Seal surfaces must be free of dirt and oil.
1. Apply Silicone Gasket and Sealant to the end of

the keyway slot.
Note
• Lubricate the oil seal contact of the
crankshaft pulley with engine oil.
atraaw00000345
2. Using the SST, install the crankshaft pulley.

303-102
(49 UN01 002)
atraaw00000346
3. Install the new bolt and the washer and tighten in

four steps.
• 1st step: Tighten to 120 N·m {12.2 kgf·m,

88.5 ft·lbf}
• 2nd step: Loosen 360 °
• 3rd step: Tighten to 47—53 N·m {4.8—5.4
• 4th step: Tighten an additional 85 °—95 °
atraaw00000343
01-10B–31
4. Remove the SST.
49 E011 1A1 49 H012 006 or M8 x1.25
5. Install the front drive belt. (See 01-10B-4 DRIVE length 40 mm {1.5 in}
Duratec)].)
End Of Sie
WM: CYLINDER HEAD
49 S120 710
atraaw00000342
CYLINDER HEAD (LH) REMOVAL/INSTALLATION[AJ (3.0L Duratec)]

id0110a3802400
Removal
1. Remove the camshafts (LH). (See 01-10B-22 CAMSHAFT (LH) REMOVAL/INSTALLATION[AJ (3.0L
Duratec)].)
2. Remove the intake manifold. (See 01-13B-4 INTAKE MANIFOLD REMOVAL/INSTALLATION[AJ (3.0L
Duratec)].)
3. Remove the coolant bypass tube.
4. Remove the exhaust manifold (LH) nuts.
Caution
• The rocker arm must be installed in its
original position.
atraaw00000038
5. Remove the rocker arm.
atraaw00000039
6. Remove the HLA.
Note
• The cylinder head bolts must be replaced
with new bolts. The bolts are torque-to-yield
designed and cannot be reused.
atraaw00000040
01-10B–32
7. Remove the bolts in the sequence shown and
remove the cylinder head.
• Discard the gasket and the bolts.
1 2
5 8
01
7 6
3 4
atraaw00000041
Installation
Caution
• Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean
the sealing surfaces. These tools cause scratches and gouges which make leak paths. Use a
plastic scraping tool to remove all traces of the head gasket. Clean all sealing surfaces with Metal
Surface Cleaner.
Note
• The cylinder head bolts must be replaced with new bolts. The bolts are torque-to-yield designed and
cannot be reused.
1. Position the cylinder head, gasket and install the

bolts in the sequence shown.
• 1st step: Tighten to 37—43 N·m {3.8—4.3 8 7

• 2nd step: Tighten bolts 85 °—90 °
• 3rd step: Loosen to 360 °
• 4th step: Tighten to 37—43 N·m {3.8—4.3 4 1

• 5th step: Tighten 85 °—90 °
2 3
6 5
atraaw00000042
2. Lubricate the HLA with engine oil and install HLA.
atraaw00000040
01-10B–33
3. Lubricate the rocker arm with engine oil and
install the rocker arm.
atraaw00000039
4. Install the exhaust manifold (LH) nuts in the

sequence shown. 1 4
5. Install the coolant bypass tube.
6. Install the intake manifold. (See 01-13B-4 INTAKE
MANIFOLD REMOVAL/INSTALLATION[AJ (3.0L
Duratec)].)
7. Install the camshaft (LH). (See 01-10B-22 5 6
CAMSHAFT (LH) REMOVAL/INSTALLATION[AJ
(3.0L Duratec)].) 19.1—25.9 N·m
3 {1.95—3.64 kgf·m,14.1—19.1 ft·lbf}
8. Inspect the compression. (See 01-10B-6
COMPRESSION INSPECTION[AJ (3.0L 2
Duratec)].)
atraaw00000043
End Of Sie
CYLINDER HEAD (RH) REMOVAL/INSTALLATION[AJ (3.0L Duratec)]
id0110a3802500
Removal
1. Remove the camshafts (RH). (See 01-10B-25 CAMSHAFT (RH) REMOVAL/INSTALLATION[AJ (3.0L
Duratec)].)
Duratec)].)
3. Remove the coolant bypass tube.
4. Remove the EGR pipe. (See 01-16B-7 EGR PIPE REMOVAL/INSTALLATION[AJ (3.0L Duratec)].)
5. Remove the exhaust manifold (RH) nuts.
Caution
• The rocker arm must be installed in its
original position.
atraaw00000052
6. Remove the rocker arm.
Caution
• The HLA must be installed in its original
position.
atraaw00000053
01-10B–34
7. Remove the HLA.
Note
• The cylinder head bolts must be replaced
with new bolts. They are torque-to-yield
designed and cannot be reused.
01
atraaw00000054
8. Remove the bolts in the sequence shown and

remove the cylinder head. 3 7 5 1
• Discard the gasket and the bolts.
4 6 8 2
atraaw00000055
Installation
Caution
the sealing surfaces. These tools cause scratches and gouges which make leak paths. Use a
plastic scraping tool to remove all traces of the head gasket. Clean all sealing surfaces with Metal
Surface Cleaner.
Note
• The cylinder head bolts must be replaced with new bolts. They are torque-to-yield designed and cannot be
reused.
1. Position the RH cylinder head, gasket and install

the bolts in the sequence shown. 6 2 4 8
• 1st step: Tighten to 37—43 N·m {3.8—4.3

• 2nd step: Tighten bolts 85 °—90 °
• 3rd step: Loosen to 360 °
• 4th step: Tighten to 37—43 N·m {3.8—4.3
• 6th step: Tighten 85 °—90 ° 5 3 1 7
atraaw00000056
2. Lubricate the HLA with engine oil and install the

HLA.
atraaw00000054
01-10B–35
3. Lubricate the rocker arm with engine oil and
install the rocker arm.
atraaw00000053
4. Install exhaust manifold (RH) nuts in the

sequence shown. 6 4 1 2 3 5
5. Install the EGR pipe. (See 01-16B-7 EGR PIPE
6. Install the coolant bypass tube.
7. Install the intake manifold. (See 01-13B-4 INTAKE
MANIFOLD REMOVAL/INSTALLATION[AJ (3.0L
Duratec)].)
8. Install the camshafts (RH). (See 01-10B-25
CAMSHAFT (RH) REMOVAL/INSTALLATION[AJ 19.1—25.9 N·m
(3.0L Duratec)].) {1.95—3.64 kgf·m,14.1—19.1 ft·lbf}
9. Inspect the compression. (See 01-10B-6
atraaw00000057
COMPRESSION INSPECTION[AJ (3.0L
Duratec)].)
End Of Sie
FRONT OIL SEAL REMOVAL/INSTALLATION[AJ (3.0L Duratec)]
WM: FRONT OIL SEAL
id0110a3802900
Removal
1. Remove the crankshaft pulley. (See 01-10B-30 CRANKSHAFT PULLEY REMOVAL/INSTALLATION[AJ (3.0L
Duratec)].)
2. Using a flathead screwdriver, remove the front oil
seal.
FRONT
OIL SEAL
aesffw00000445
Installation
1. Combine SST [303-335 (49 UN30 3335)]
component A with SST [303-102 (49 UN01 002)].
COMPONENT A
303-102
(49 UN01 002) 303-335
(49 UN30 3335)
aesffw00000446
01-10B–36
2. Using the SST, install the front oil seal.
303-335 ENGINE
3. Install the crankshaft pulley. (See 01-10B-30 FRONT COVER
(49 UN30 3335)
CRANKSHAFT PULLEY REMOVAL/
End Of Sie
WM: REAR OIL SEAL
OIL
SEAL
0—1.0 mm
{0—0.039 in}
01
303-102
(49 UN01 002)
aesffw00000447
REAR OIL SEAL REMOVAL/INSTALLATION[AJ (3.0L Duratec)]

id0110a3803100
Removal
1. Remove the drive plate. (See 05-17B-65 DRIVE PLATE REMOVAL[LA4AX-EL (CD4E)].)
2. Using a flathead screwdriver, remove the rear oil
seal. REAR OIL SEAL
atraaw00000859
Installation
Note
• Lubricate the crankshaft rear oil lip with engine oil.
1. Using the SST, install the rear oil seal.

303-384
2. Install the drive plate. (See 05-17B-65 DRIVE
(49 UN30 3384)
PLATE INSTALLATION[LA4AX-EL (CD4E)].) CYLINDER
End Of Sie BLOCK
WM: ENGINE COMPLETE
0—2.0 mm
{0—0.078 in}
303-178 OIL SEAL

(49 UN01 070)
atraaw00000860
01-10B–37
No.3 ENGINE MOUNT REMOVAL/INSTALLATION[AJ (3.0L Duratec)]
id0110a3802300
Removal/Installation
2. Remove the power steering pressure hose
bracket.
100—125 N·m
{10.2—12.7 kgf·m,
73.8—92.1 ft·lbf}
atraaw00000058
3. Assemble two SSTs using the bolt (M6) and nut,

then install them in the position shown in the
6.9—9.8 N·m
figure for the cylinder head (RH). {71—99 kgf·cm,
62—86 in·lbf}
Caution
303-050
(49 UN30 3050)
100—125 N·m
{10.2—12.7 kgf·m,
73.8—92.1 ft·lbf}
atraaw00003128
MAIN FRAME
REAR SHAFT
SIDE BAR
FRONT SHAFT
FRONT FOOT No.1

FRONT FOOT No.2

atraaw00002180
01-10B–38
49 C017 5A0
the figure.
to the right side)
FRONT SIDE
01
atraaw00000060

49 C017 5A0
figure.
and horizontal.
Caution
• If the SSTs installed to the cylinder head
(RH) interfere with the brake pipe, the LH
brake pipe could be damaged. Do not
allow the SSTs to interfere with the brake
pipe.
atraaw00003129
Note 49 L017 5A0

FRONT SIDE
303-050
BRAKE PIPE (49 UN30 3050)
atraaw00000062

49 C017 5A0
49 L017 5A0
atraaw00002450
01-10B–39
6. Position the power pressure steering line and
10 N·m {1.1 kgf·m,
bracket out of the way. 7.4 ft·lbf}
atraaw00000066
7. Remove the bolts and nuts, and then remove the

No.3 engine mount bracket.
45.5—64.5 N·m
8. Install in the reverse order of removal. 74.5—104.9 N·m
{4.64—6.57 kgf·m,
{7.60—10.69 kgf·m,
End Of Sie 55.0—77.3 ft·lbf} 33.6—47.5 ft·lbf}
97.7—132.3 N·m
{9.97—13.50 kgf·m,
72.1—97.5 ft·lbf}
74.5—104.9 N·m
{7.60—10.69 kgf·m,
55.0—77.3 ft·lbf}
atraaw00000071
ENGINE REMOVAL[AJ (3.0L Duratec)]

id0110a3802200
Warning
• The fuel system contains pressurized and highly flammable fuel that can cause death or serious
injury, and damage if it sprays or leaks out. Fuel can also irritate skin and eyes. To prevent this,
always perform the “Fuel Line Safety Procedure” before performing any procedure involving the
fuel system. (See 01-14B-4 BEFORE SERVICE PRECAUTION[AJ (3.0L Duratec)].)

2. Remove the battery tray. (See 01-17B-2 BATTERY REMOVAL/INSTALLATION[AJ (3.0L Duratec)].)
3. Remove the air cleaner outlet tube and air cleaner. (See 01-13B-4 AIR CLEANER REMOVAL/
4. Lift up the vehicle.
5. Remove the lower splash shield.
6. Drain the engine coolant. (See 01-12B-5 ENGINE COOLANT REPLACEMENT[AJ (3.0L Duratec)].)
7. Drain the engine oil. (See 01-11B-2 ENGINE OIL REPLACEMENT[AJ (3.0L Duratec)].)
8. Lower the vehicle.
9. Disconnect the fuel line. (See 01-14B-4 BEFORE SERVICE PRECAUTION[AJ (3.0L Duratec)].)
10. Remove the water pump drive belt. (See 01-10B-4 DRIVE BELT REMOVAL/INSTALLATION[AJ (3.0L
Duratec)].)
11. Disconnect the accelerator cable.
01-10B–40
12. Disconnect purge solenoid valve outlet tube.
01
atraaw00000252
13. Disconnect the PCM connector.
atraaw00000378
14. Disconnect the hoses and position the thermostat

housing and hose assembly out of the way.
atraaw00000912
15. Disconnect the connector from BJB.
atraaw00000256
16. Remove the BJB cover.
atraaw00000257
01-10B–41
17. Remove the nuts and the cables.
atraaw00002973
18. Disconnect the selector cable.
atraaw00000333
19. Disconnect the brake vacuum hose.
atraaw00000260
20. Disconnect the vacuum line.
atraaw00000261
21. Disconnect the heater hoses.
atraaw00000262
01-10B–42
22. Disconnect the power steering return line.
01
atraaw00000263
23. Disconnect the power steering pressure line.

• Disconnect the PSP switch connector.
• Remove the bracket bolt.
• Disconnect the power steering pressure line.
atraaw00000264
24. Remove the dipstick.

25. Remove the front pipe. (See 01-15B-4 FRONT
PIPE REMOVAL/INSTALLATION[AJ (3.0L
Duratec)].)
26. Remove the catalytic converter. (See 01-16B-9
CATALYTIC CONVERTER REMOVAL/
27. Remove the A/C compressor. Do not disconnect
the A/C compressor pipe while positioning it out
of the way.
28. Remove both the front wheels and tires. (See 02-
12-7 WHEEL AND TIRE REMOVAL/
atraaw00000265
INSTALLATION.)
29. Remove the propeller shaft. (See 03-15-4
PROPELLER SHAFT REMOVAL/INSTALLATION.)
30. Separate the LH and RH ball joints.
atraaw00000266
01-10B–43
31. Separate the LH and RH tie-rod ends from the
steering knuckle using the SST.
49 T028 3A0
atraaw00000267
32. Separate the LH and RH stabilizer control link

from the shock absorber.
atraaw00000268
33. Remove the bolt and position the LH and RH ABS

sensors out of the way.
atraaw00000269
34. Remove the LH and RH brake calipers from the

steering knuckles and support the struts.
35. Remove the boot mounting nut.
atraaw00000270
36. Separate the bolt between the steering shaft and

steering gear.
• Loosen the bolt between the steering shaft
and steering shaft.
(1) Slide the boot to the upper area.
2
atraaw00000271
01-10B–44
37. Remove the transaxle line bracket bolt.
01
atraaw00000272
38. Disconnect the two transaxle cooler lines.
atraaw00000273
39. Remove the torque converter inspection cover.
atraaw00000274
40. Remove the torque converter nuts.
atraaw00000275
41. Remove the four bolts.

42. Determine the appropriate lift position.
Note
• The next six steps must be carried out with
the vehicle raised and the universal
powertrain lift in position.
atraaw00000276
01-10B–45
43. Remove the bolts and nuts, and then remove the
No.3 engine mount bracket.
atraaw00000822
44. Remove the bolts and No.4 engine mount rubber.
atraaw00000278
45. Remove two front cross member bolts.
atraaw00000279
46. Remove two front cross member nuts.
atraaw00000280
47. Remove the four bolts from the engine mount

member.
48. Remove the transaxle from the vehicle.
atraaw00000281
01-10B–46
49. Remove the power steering pressure hose
bracket.
01
aesffw00000390
6.9—9.8 N·m
62—86 in·lbf}
Caution
303-050
(RH) interfere with the brake pipe, the
(49 UN30 3050)
100—125 N·m
pipe. {10.2—12.7 kgf·m,
73.8—92.1 ft·lbf}
aesffw00000391
49 L017 5A0
FRONT SIDE
303-050
atraaw00000062
51. Using the SST, remove the transaxle from the lift
and set it down on the floor or a suitable table. 303-050
(49 UN30 3050) 49 L017 5A0
atraaw00000283
52. Disconnect the HO2S.
atraaw00000284
01-10B–47
53. Disconnect the TR switch.
atraaw00000285
54. Disconnect the transaxle connector.
atraaw00000286
55. Remove the bolt and separate the transaxle

control harness from the bracket.
atraaw00000287
56. Remove the two bolts, the starter and wiring

harness.
atraaw00000288
57. Disconnect the KS jumper electrical connector.
atraaw00000289
01-10B–48
58. Disconnect the OSS sensor electrical connector.
01
atraaw00000290
59. Disconnect the HO2S and the EGR tube from the
exhaust manifold.
atraaw00000291
60. Remove the generator.

(1) Disconnect the connector.
1
atraaw00000292
61. Remove the six RH exhaust manifold nuts and

gasket.
atraaw00000293
62. Remove the bolts and position the joint bracket

out of the way.
atraaw00000294
01-10B–49
63. Remove the five transaxle bolts.
64. Remove the engine from the transaxle.
End Of Sie
atraaw00000295
ENGINE INSTALLATION[AJ (3.0L Duratec)]

id0110a3802000
6.9—9.8 N·m
2. Install with the transaxle on the crossmember. 62—86 in·lbf}
303-050
(49 UN30 3050)
100—125 N·m
{10.2—12.7 kgf·m,
73.8—92.1 ft·lbf}
aesffw00000389
3. Install the five bolts to the transaxle.
38—57 N·m
{3.9—5.8 kgf·m, 29—42 ft·lbf}
atraaw00000297
4. Position the joints haft bracket and install the

bolts.
40.3—54.7 N·m
{4.11—5.57 kgf·m, 29.8—40.3 ft·lbf}
atraaw00000298
01-10B–50
5. Install a new gasket and the RH exhaust manifold.
1 5
4 3
6 2 01
19.1—25.9 N·m
{1.95—2.64 kgf·m,14.1—19.1 ft·lbf}
atraaw00000299
6. Install the generator.
40—50 N·m {4.1— 5.0

7.2—10.8 N·m {73.5—110

kgf·cm, 63.8—95.4 in·lbf}
atraaw00000300
7. Connect the EGR pipe and the HO2S connector.
34—45 N·m {3.6—4.5

atraaw00000301
8. Connect the OSS sensor connector.
atraaw00000302
01-10B–51
9. Connect the KS connector.
atraaw00000303
10. Install the starter.
37.3—52 N·m
{3.8—5.3 kgf·m, 27.5—38.3 ft·lbf}
atraaw00000304
11. Install the bolt and connect the transaxle harness

to the bracket.
19—25 N·m
{2.0—2.5 kgf·m, 15—18 ft·lbf}
atraaw00000305
12. Connect the transaxle harness.
atraaw00000306
13. Connect the TR switch.
atraaw00000307
01-10B–52
14. Connect the HO2S sensors.
Caution
(RH) interfere with the brake pipe, the
pipe.
01
atraaw00000308
49 L017 5A0
FRONT SIDE
303-050
atraaw00000062
15. Using the SST, position the engine and transaxle 303-050
on a suitable lift. 49 L017 5A0
(49 UN30 3050)
16. Install the engine and transaxle in the vehicle.
atraaw00000309
17. Install the four bolts to the engine mount member.
66.6—93.1 N·m
{6.80—9.49 kgf·m, 49.2—68.6 ft·lbf}
atraaw00000310
18. Install the two front crossmember nuts.

127.5—172.5 N·m
{13.01—17.59 kgf·m,
94.1—127.2 ft·lbf}
atraaw00000311
01-10B–53
19. Install the two front crossmember bolts.
133—178 N·m
{13.6—18.1 kgf·m,
99—131 ft·lbf}
atraaw00000312
20. Position the No.4 engine mount rubber and install 58.8—80.4 N·m
the bolts. {6.00—8.19 kgf·m, 43.4—59.3 ft·lbf}
Note
• The next two steps must be carried out with
the vehicle raised and the engine and
transaxle supported by the lift.
66.6—93.1 N·m
{6.80—9.49 kgf·m, 49.2—68.6 ft·lbf}
atraaw00000313
21. Install No.3 engine mount bracket, bolts and nuts.

22. Remove the lift.
74.5—104.9 N·m 45.5—64.5 N·m
{7.60—10.69 kgf·m, {4.64—6.57 kgf·m,
55.0—77.3 ft·lbf} 33.6—47.5 ft·lbf}
97.7—132.3 N·m
{9.97—13.50 kgf·m,
72.1—97.5 ft·lbf}
74.5—104.9 N·m
{7.60—10.69 kgf·m,
55.0—77.3 ft·lbf}
atraaw00001179
23. Install the four bolts.

38—57 N·m
{3.9—5.8 kgf·m, 29—42 ft·lbf}
atraaw00000315
01-10B–54
24. Install the four torque converter mounting nuts.
34—46 N·m
{3.5—4.6 kgf·m, 25—33 ft·lbf}
01
atraaw00000316
25. Install the access cover.
atraaw00000317
26. Connect the two transaxle cooler lines.
atraaw00000318
27. Install the cooler line bracket bolt.

21.2—28.8 N·m
{2.2—2.9 kgf·m, 15.7—21.2 ft·lbf}
atraaw00000319
28. Install the bolt between the steering shaft and

24 N·m {2.4 kgf·m,
steering gear. 18 ft·lbf}
atraaw00000320
01-10B–55
29. Connect the LH and RH struts to the steering
knuckles and install the bolts.
93.1—116.62 N·m
{9.494—11.691 kgf·m,
68.67—86.01 ft·lbf}
atraaw00000321
30. Install the brake calipers to the steering knuckle.
127.5—172.5 N·m
{13.01—17.59 kgf·m, 94.1—127.2 ft·lbf}
atraaw00000322
31. Position the LH and RH ABS sensors and install

the bolts.
7.8—10.8 N·m
{80—110 kgf·cm,
69.1—95.5 ft·lbf}
atraaw00000323
32. Connect the LH and RH stabilizer control link to

43.1—60.8 N·m
the shock absorber. {4.40—6.19 kgf·m,
31.8—44.8 ft·lbf}
atraaw00000324
33. Connect the LH and RH tie-rod ends to the

steering knuckle.
46.8—63.6 N·m
{4.98—6.48 kgf·m,
36.0—46.9 ft·lbf}
atraaw00000325
01-10B–56
34. Connect the LH and RH ball joints.
35. Install the propeller shaft. (See 03-15-4 43.1—60.8 N·m
PROPELLER SHAFT REMOVAL/ {4.40—6.19 kgf·m,
INSTALLATION.) 31.8—44.8 ft·lbf}
36. Install both front wheel and tire assemblies. (See
02-12-7 WHEEL AND TIRE REMOVAL/
INSTALLATION.)
37. Install the A/C compressor.
38. Install the catalytic converter. (See 01-16B-9
CATALYTIC CONVERTER REMOVAL/
01
39. Install the front tube. (See 01-15B-4 FRONT PIPE
atraaw00000326
40. Install the lower splash shield.
41. Install the power steering pressure hose bracket.
100—125 N·m
{10.2—12.7 kgf·m,
73.8—92.1 ft·lbf}
atraaw00000058
43. Install the dipstick.
atraaw00000327
44. Connect the power steering pressure line.

• Install the bracket bolt.
• Connect the PSP switch connector.
• Connect the power steering pressure line. 10 N·m
{102 kgf·cm, 89 in·lbf}
65 N·m
{6.6 kgf·m, 48 ft·lbf}
atraaw00000328
01-10B–57
45. Connect the power steering return line.
atraaw00000329
46. Connect the heater hoses.
atraaw00000330
47. Connect the vacuum line.
atraaw00000331
48. Connect the brake vacuum hose.
atraaw00000332
49. Connect the selector cable.
atraaw00000333
01-10B–58
50. Install the cables and the nuts.
8.0—11.0 N·m
{82—112 kgf·cm, 71—97 in·lbf}
01
atraaw00000334
51. Install the BJB cover.
atraaw00000335
52. Connect the connector to the BJB.
atraaw00000336
53. Position the thermostat housing and connect the

five hoses.
atraaw00000913
54. Connect the PCM connector.
3.0—5.4 N·m
{31—55 kgf·cm, 27—47 in·lbf}
atraaw00000382
01-10B–59
55. Connect the purge solenoid valve outlet tube.
56. Connect the accelerator cable.
57. Connect the fuel line. (See 01-14B-4 BEFORE
SERVICE PRECAUTION[AJ (3.0L Duratec)].)
58. Install the air cleaner outlet tube and air cleaner.
(See 01-13B-4 AIR CLEANER REMOVAL/
59. Install the battery and the battery tray. (See 01-
17B-2 BATTERY REMOVAL/INSTALLATION[AJ
(3.0L Duratec)].)
60. Install the water pump drive belt. (See 01-10B-4
DRIVE BELT REMOVAL/INSTALLATION[AJ (3.0L
atraaw00000340
Duratec)].)
61. Refill the engine coolant. (See 01-12B-5 ENGINE
COOLANT REPLACEMENT[AJ (3.0L Duratec)].)
62. Refill the crankcase with oil. (See 01-11B-2 ENGINE OIL REPLACEMENT[AJ (3.0L Duratec)].)
63. Start the engine, and inspect and adjust the following:
• Runout and contact of the pulley and belt
• Leakage of engine oil, engine coolant, ATF and fuel
• Ignition timing, idle speed, and idle mixture (CO and HC concentration) (See 01-10B-61 ENGINE TUNE-
UP[AJ (3.0L Duratec)].)
• Engine-driven accessories operation
Note
• If there is any malfunction, loosen the engine mount installation bolts and nuts, and adjust the engine
installation position.
• If installing an overhauled engine, perform a road test and verify that there is no abnormal vibration or
noise.
End Of Sie
ENGINE DISASSEMBLY/ASSEMBLY[AJ (3.0L Duratec)]
id0110a3800500
1. Remove the CKP sensor. (See 01-40B-23 CRANKSHAFT POSITION (CKP) SENSOR REMOVAL/
2. Remove the CMP sensor. (See 01-40B-24 CAMSHAFT POSITION (CMP) SENSOR REMOVAL/
Duratec)].)
Duratec)].)
5. Remove the thermostat case and water hose
component.
6. Remove the water bypass tube.
7. Remove the Ignition coils. (See 01-18B-2
IGNITION COIL REMOVAL/INSTALLATION[AJ
(3.0L Duratec)].)
atraaw00000911
8. Remove the generator bracket.

End Of Sie
25 N·m {2.5 kgf·m,

18 ft·lbf}
atraaw00000348
01-10B–60
ENGINE TUNE-UP[AJ (3.0L Duratec)]
id0110a3800600
Engine Tune-up Preparation
1. Turn off the electrical loads.
(1) Increase the engine speed to between 2,500 and 3,000 rpm until the main fan and additional fan start
operating.
(2) When the main fan and additional fan start operating, release the accelerator pedal and wait until the fans
stop operating.
3. Connect the PDS/IDS to the DLC-2. 01
DLC-2
aesffw00000034
Ignition Timing Inspection
Note
• Ignition timing is not adjustable.
• Ignition timing verification requires PDS/IDS.
1. Perform the engine tune-up preparation.

2. Verify that the ignition timing (PDS/IDS: SPARKADV PID) is within the specification using PDS/IDS.
Ignition timing
BTDC 8 °—12 ° (700—800 rpm)
3. Verify that ignition timing advances when the engine speed increases gradually.
• If there is malfunction, refer to “ENGINE SYMPTOM TROUBLESHOOTING”. (See 01-03B-4 ENGINE
SYMPTOM TROUBLESHOOTING[AJ (3.0L Duratec)].)
Idle Speed Inspection
Note
• Idle speed is not adjustable.
• Idle speed verification requires PDS/IDS.
1. Perform the engine tune-up preparation.

2. Verify that the idle speed (PDS/IDS: RPM PID) is within the specification using PDS/IDS.
SYMPTOM TROUBLESHOOTING[AJ (3.0L Duratec)].)
Idle speed
600—900 rpm (P position)
Idle Mixture Inspection

(1) Increase the engine speed to between 2,500 and 3,000 rpm until the main fan and additional fan start
operating.
(2) When the main fan and additional fan start operating, release the accelerator pedal and wait until the fans
stop operating.
2. Insert an exhaust gas analyzer to the tailpipe.
3. Verify that the CO and HC concentrations are within the regulation.
SYMPTOM TROUBLESHOOTING[AJ (3.0L Duratec)].))
Idle mixture
End Of Sie
01-10B–61
LUBRICATION [L3]
01-11A LUBRICATION [L3]

LUBRICATION SYSTEM LOCATION OIL FILTER REPLACEMENT[L3] . . . . . . 01-11A–4
INDEX[L3] . . . . . . . . . . . . . . . . . . . . . . . 01-11A–1 OIL PAN REMOVAL/INSTALLATION
ENGINE OIL LEVEL INSPECTION [L3] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-11A–4
[L3] . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-11A–2 OIL PUMP REMOVAL/INSTALLATION
ENGINE OIL REPLACEMENT[L3] . . . . . 01-11A–2 [L3] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-11A–7
OIL PRESSURE INSPECTION[L3]. . . . . 01-11A–3
01
End of Toc
LUBRICATION SYSTEM LOCATION INDEX[L3]
WM: LUBRICATION SYSTEM
id0111a1800100
2
6
5
3
OIL PAN DRAIN PLUG
WASHER 4
atraaw00000410
1 Dipstick 4 Oil pan

(See 01-11A-2 ENGINE OIL LEVEL (See 01-11A-4 OIL PAN REMOVAL/
INSPECTION[L3].) INSTALLATION[L3].)
(See 01-11A-2 ENGINE OIL REPLACEMENT[L3].) 5 Oil strainer
2 Oil pressure switch (See 01-11A-7 OIL PUMP REMOVAL/
(See 01-11A-3 OIL PRESSURE INSPECTION[L3].) INSTALLATION[L3].)
3 Oil filter 6 Oil pump component
(See 01-11A-4 OIL FILTER REPLACEMENT[L3].) (See 01-11A-7 OIL PUMP REMOVAL/
INSTALLATION[L3].)
End Of Sie
WM: ENGINE OIL
01-11A–1
LUBRICATION [L3]
ENGINE OIL LEVEL INSPECTION[L3]
id0111a1800500
1. Position the vehicle on level ground.
3. Stop the engine and allow approx. 5 min before continuing.
4. Remove the dipstick and verify that the oil level is
between the F and L marks on the dipstick.
• If the oil level is below the L mark, add engine
oil.
End Of Sie
L MARK F MARK
atraaw00000564
ENGINE OIL REPLACEMENT[L3]

id0111a1800400
Warning
• Hot engines and engine oil can cause severe burns. Turn off the engine and wait until it and the
engine oil have cooled.
• A vehicle that is lifted but not securely supported on safety stands is dangerous. It can slip or fall,
causing death or serious injury. Never work around or under a lifted vehicle if it is not securely
supported on safety stands.
• Continuous exposure to USED engine oil has caused skin cancer in laboratory mice. Protect your
skin by washing with soap and water immediately after working with engine oil.
Caution
• If engine oil is spilled on the exhaust system, wipe it off completely. If you fail to wipe the spilled
engine oil, it will produce fumes because of the heat.

2. Remove the oil filler cap.
3. Remove the oil pan drain plug.
4. Drain the engine oil into a container.
5. Install the oil pan drain plug with a new washer.
Oil pan drain plug tightening torque

30—41 N·m {3.1—4.1 kgf·m, 23—30 ft·lbf}
Note
• The amount of residual oil in the engine can vary according to factors such as the replacement method
and oil temperature. Verify the oil level after engine oil replacement.
6. Refill with the following type and amount of the engine oil.
Note
• The maintenance intervals on scheduled maintenance table (See 00-00-34 SCHEDULED
MAINTENANCE) can only be supported with the use of the following oils.
Recommended engine oil

Item Specification
Grade API SG/SH/SJ/SL or ILSAC GF–2/GF–3
40, 30, 20, 20W–20, 10W–30, 10W–40, 10W–50,
Viscosity (SAE)
20W–40, 15W–40, 20W–50, 15W–50, 5W–20, 5W–30
Engine oil capacity (approx. quantity)

Oil replacement: 4.0 L {4.2 US qt, 3.5 Imp qt}
Oil and oil filter replacement: 4.4 L {4.6 US qt, 3.9 Imp qt}
Total (dry engine): 5.1 L {5.4 US qt, 4.5 Imp qt}
7. Install the oil filler cap.
01-11A–2
LUBRICATION [L3]
8. Start the engine and confirm that there is no oil leakage.
• If there is oil leakage, repair or replace the applicable part.
9. Inspect the oil level. (See 01-11A-2 ENGINE OIL LEVEL INSPECTION[L3].)
End Of Sie
OIL PRESSURE INSPECTION[L3]
WM: OIL PRESSURE
id0111a1800300
Warning
engine oil have cooled. 01

2. Position the both splash shields out of the way.
3. Remove the oil pressure switch.
4. Screw the SSTs into the oil pressure switch
installation hole.
5. Connect the negative battery cable.
6. Warm up the engine to normal operating 49 0187 280A
temperature.
7. Run the engine at the specified speed, and note
the gauge readings.
• If not within the specification, inspect for the
cause and repair or replace if necessary. 49 H019 002
Note 49 E019 001

• The oil pressure can vary with oil viscosity
atraaw00000418
and temperature.
Oil pressure (reference value) [oil temperature: 100 °C {212 °F}]

337—591 kPa {3.44—6.03 kgf/cm2, 49.0—85.8 psi} [3,000 rpm]
8. Stop the engine and wait until it is cool.

10. Remove the SSTs.
Caution
• Make sure that there is no sealant between 1.0—2.0 mm {0.04—0.07 in} from the end of the oil
pressure switch to prevent a possible operation malfunction.
11. Apply silicone sealant to the oil pressure switch

threads as shown in the figure.
12. Install the oil pressure switch. 1.0—2.0 mm {0.04—0.07 in}
Tightening torque
12—18 N·m {1.3—1.8 kgf·m, 9—13 ft·lbf}

14. Start the engine and confirm that there is no oil
leakage. SEALANT
• If there is oil leakage, repair or replace the

applicable part.
atraaw00000419
15. Install the splash shield (RH).
End Of Sie
WM: OIL FILTER
01-11A–3
LUBRICATION [L3]
OIL FILTER REPLACEMENT[L3]
id0111a1800700
Warning
Caution
1. Position the splash shield (RH) out of the way.

2. Remove the oil filter using a commercially
available, cup-type oil filter wrench (76 mm {3.0
in} diameter, 15 sided).
3. Use a clean rag to wipe off the mounting surface.
4. Apply clean engine oil to the O-ring of a new oil
filter.
5. Tighten the oil filter using a cup-type oil filter
wrench and according to the instructions on the
package or side of the oil filter.
Tightening torque (reference value)

15—20 N·m {1.6—2.0 kgf·m, 11—14 ft·lbf}
atraaw00000423
6. Start the engine and confirm that there is no oil

leakage.
End Of Sie
OIL PAN REMOVAL/INSTALLATION[L3]
WM: OIL PAN
id0111a1800200
Warning

2. Remove the front tire (RH).
3. Remove the both splash shields.
4. Drain the engine oil. (See 01-11A-2 ENGINE OIL REPLACEMENT[L3].)
5. Loosen the water pump pulley bolts before removing the drive belt.
6. Remove the drive belt. (See 01-10A-3 DRIVE BELT REMOVAL/INSTALLATION[L3].)
7. Remove the ignition coils. (See 01-18A-2 IGNITION COIL REMOVAL/INSTALLATION[L3].)
8. Remove the P/S oil pump with the hose and pipe still connected. Position the P/S oil pump out of the way. (See
06-14-37 POWER STEERING OIL PUMP REMOVAL/INSTALLATION[L3].)
9. Remove the crankshaft position (CKP) sensor. (See 01-40A-37 CRANKSHAFT POSITION (CKP) SENSOR
REMOVAL/INSTALLATION[L3].)
10. Remove the engine front cover. (See 01-10A-10 TIMING CHAIN REMOVAL/INSTALLATION[L3].)
13. Refill with the specified type and amount of the engine oil. (See 01-11A-2 ENGINE OIL REPLACEMENT[L3].)
01-11A–4
LUBRICATION [L3]
16. Inspect for the ignition timing and idle speed. (See 01-10A-34 ENGINE TUNE-UP[L3].)
37—52 {3.8—5.3,
28—38}
01
SEALANT
17—23 {1.8—2.3, 12.6—16.9}
17—23 {1.8—2.3, 12.6—16.9}
37—52 {3.8—5.3, 28—38} N·m {kgf·m, ft·lbf}
atraaw00000411
1 Oil pan
(See 01-11A-5 Oil Pan Removal Note.)
(See 01-11A-5 Oil Pan Installation Note.)
Oil Pan Removal Note

1. Remove the oil pan using a separator tool.
atraaw00000412
Oil Pan Installation Note
Caution
• Apply the silicon sealant in a single, unbroken line around the whole perimeter.
• Using bolts with the old seal adhering could cause cracks in the housing.
1. Completely clean and remove any oil, dirt, sealant

or other foreign material that may be adhering to
the housing and oil pan.
2. When reusing the oil pan installation bolts, clean DAMAGE
any old sealant from the bolts.
OLD SEALANT
atraaw00000413
01-11A–5
LUBRICATION [L3]
3. Use a square ruler to align the oil pan and the
cylinder block junction side on the engine front
cover side.
atraaw00000414
4. Apply silicone sealant to the oil pan along the

inside of the bolt holes as shown in the figure.
Thickness 2.2—3.2 mm
2.2—3.2 mm {0.087—0.126 in} {0.087—0.126 in}
atraaw00000415
5. Tighten the bolts in the order shown in the figure.

13 8 4 1 5 9
Tightening torque
17—23 N·m {1.8—2.3 kgf·m, 12.6—16.9
ft·lbf} 10
11
12 7 3 2 6
atraaw00000416
6. Tighten the oil pan-transaxle installation bolts.
Tightening torque
37—52 N·m {3.8—5.3 kgf·m, 28—38 ft·lbf}
End Of Sie
WM: OIL PUMP
OIL PAN-TRANSAXLE INSTALLATION BOLTS

atraaw00000417
01-11A–6
LUBRICATION [L3]
OIL PUMP REMOVAL/INSTALLATION[L3]
id0111a1800600
Warning
• Hot engines and engines oil can cause severe burns. Turn off the engine and wait until it and the
• Continuous exposure to USED engine oil has caused skin cancer in laboratory mice. Protect your 01

2. Remove the front tire (RH).
4. Drain the engine oil. (See 01-11A-2 ENGINE OIL REPLACEMENT[L3].)
8. Remove the P/S oil pump with the hose and pipe still connected. Position the P/S oil pump out of the way. (See
06-14-37 POWER STEERING OIL PUMP REMOVAL/INSTALLATION[L3].)
9. Remove the crankshaft position (CKP) sensor. (See 01-40A-37 CRANKSHAFT POSITION (CKP) SENSOR
10. Remove the engine front cover. (See 01-10A-10 TIMING CHAIN REMOVAL/INSTALLATION[L3].)
11. Remove the oil pan. (See 01-11A-4 OIL PAN REMOVAL/INSTALLATION[L3].)
14. Refill with the specified type and amount of the engine oil. (See 01-11A-2 ENGINE OIL REPLACEMENT[L3].)
17. Inspect for the ignition timing and idle speed. (See 01-10A-34 ENGINE TUNE-UP[L3].)
18. Inspect the oil pressure. (See 01-11A-3 OIL PRESSURE INSPECTION[L3].)
2
8.0—11.5
{82—117,
71—101}
4
3
B
SST 5
6
R
OIL
8.0—11.5
{82—117,
1
71—101}
A : 20—30 N·m {2.1—3.0 kgf·m, 14.8—22.1 ft·lbf}

N·m {kgf·cm, in·lbf}
B : 8—12 N·m {82—122 kgf·cm, 71—105 in·lbf}, 17—23 N·m {1.8—2.3 kgf·m, 12.6—16.9 ft·lbf}
atraaw00000420
1 Oil strainer 5 Oil pump sprocket

2 Oil pump chain guide (See 01-11A-8 Oil Pump Sprocket Removal/
Installation Note.)
3 Oil pump chain tensioner
6 Oil pump
4 Oil pump chain (See 01-11A-8 Oil Pump Installation Note.)
01-11A–7
LUBRICATION [L3]
Oil Pump Sprocket Removal/Installation Note
1. Install the SST to the oil pump sprocket to stop
the oil pump from rotating.
49 G032 354
atraaw00000421
Oil Pump Installation Note

1. Tighten the oil pump bolts in two steps in the
order shown in the figure.
1
Tightening torque 4
Step 1: 8—12 N·m {82—122 kgf·cm, 71—105
in·lbf}
Step 2: 17—23 N·m {1.8—2.3 kgf·m, 12.6—
16.9 ft·lbf}
3
End Of Sie 2
atraaw00000422
01-11A–8
LUBRICATION [AJ (3.0L Duratec)]
01-11B LUBRICATION [AJ (3.0L Duratec)]

LUBRICATION SYSTEM LOCATION OIL COOLER
INDEX[AJ (3.0L Duratec)] . . . . . . . . . . 01-11B–1 REMOVAL/INSTALLATION
ENGINE OIL LEVEL INSPECTION [AJ (3.0L Duratec)] . . . . . . . . . . . . . . . . 01-11B–4
[AJ (3.0L Duratec)] . . . . . . . . . . . . . . . . 01-11B–2 OIL PAN REMOVAL/INSTALLATION
ENGINE OIL REPLACEMENT [AJ (3.0L Duratec)] . . . . . . . . . . . . . . . . 01-11B–5
[AJ (3.0L Duratec)] . . . . . . . . . . . . . . . . 01-11B–2 OIL PUMP REMOVAL/INSTALLATION
OIL PRESSURE INSPECTION [AJ (3.0L Duratec)] . . . . . . . . . . . . . . . . 01-11B–7 01
[AJ (3.0L Duratec)] . . . . . . . . . . . . . . . . 01-11B–3 OIL STRAINER
OIL FILTER REPLACEMENT REMOVAL/INSTALLATION
End of Toc
LUBRICATION SYSTEM LOCATION INDEX[AJ (3.0L Duratec)]
WM: LUBRICATION SYSTEM
id0111a2800100
7
1
4 3
OIL PAN DRAIN PLUG
atraaw00000424
1 Dipstick 4 Oil cooler

(See 01-11B-2 ENGINE OIL LEVEL (See 01-11B-4 OIL COOLER REMOVAL/
INSPECTION[AJ (3.0L Duratec)].) INSTALLATION[AJ (3.0L Duratec)].)
(See 01-11B-2 ENGINE OIL REPLACEMENT[AJ 5 Oil pan
(3.0L Duratec)].) (See 01-11B-5 OIL PAN REMOVAL/
2 Oil pressure switch INSTALLATION[AJ (3.0L Duratec)].)
(See 01-11B-3 OIL PRESSURE INSPECTION[AJ 6 Oil strainer
(3.0L Duratec)].) (See 01-11B-8 OIL STRAINER REMOVAL/
3 Oil filter INSTALLATION[AJ (3.0L Duratec)].)
(See 01-11B-4 OIL FILTER REPLACEMENT[AJ 7 Oil pump
(3.0L Duratec)].) (See 01-11B-7 OIL PUMP REMOVAL/
End Of Sie
WM: ENGINE OIL
01-11B–1
ENGINE OIL LEVEL INSPECTION[AJ (3.0L Duratec)]
id0111a2800500
3. Stop the engine and allow approx. 5 min before continuing.
4. Remove the dipstick and verify that the oil level is
between the F and L marks on the dipstick.
• If the oil level is below the L mark, add engine
oil.
End Of Sie
L MARK F MARK
atraaw00000431
ENGINE OIL REPLACEMENT[AJ (3.0L Duratec)]

id0111a2800400
Warning
Caution

2. Remove the oil filler cap.
3. Remove the oil pan drain plug and drain the engine oil.
4. Inspect the rubber seal of the oil pan drain plug and make sure there are no cracks, deterioration, or damage.
• If necessary, replace the oil pan drain plug.
5. Clean the flange surface (seal rubber) on the oil pan drain plug, then install the oil pan drain plug.
Tightening torque
22—30 N·m {2.3—3.0 kgf·m, 17—22 ft·lbf}
Note
• The amount of residual oil in the engine can vary according to factors such as the replacement method
and oil temperature. Verify the oil level after engine oil replacement.
6. Refill with the following type and amount of the engine oil.
Engine oil capacity (approx. quantity)

Oil and oil filter replacement: 5.7 L {6.0 US qt, 5.0 Imp qt}

Item Specification
Grade API SM or ILSAC GF–4
Viscosity (SAE) 5W–30
7. Install the oil filler cap.

9. Inspect the oil level. (See 01-11B-2 ENGINE OIL LEVEL INSPECTION[AJ (3.0L Duratec)].)
End Of Sie
WM: OIL PRESSURE
01-11B–2
OIL PRESSURE INSPECTION[AJ (3.0L Duratec)]
id0111a2800300
Warning
• Continuous exposure to USED engine oil has caused skin cancer in laboratory mice. Protect your 01

2. Remove the splash shield (RH).
3. Remove the drive belt. (See 01-10B-4 DRIVE BELT REMOVAL/INSTALLATION[AJ (3.0L Duratec)].)
4. Remove the A/C compressor with the pipes still connected and position it out of the way. (See 07-11-12 A/C
COMPRESSOR REMOVAL/INSTALLATION [AJ (3.0L Duratec)].)
5. Disconnect the oil pressure switch connector.
6. Remove the oil pressure switch.
7. Connect the SSTs to the oil pressure switch
installation hole. 49 0187 280A
8. Install the A/C compressor. (See 07-11-12 A/C
COMPRESSOR REMOVAL/INSTALLATION [AJ
(3.0L Duratec)].)
9. Install the drive belt. (See 01-10B-4 DRIVE BELT
11. Start the engine and warm it up.
12. Run the engine at the specified speed, and note
49 L014 001A
the gauge readings.
• If it is less than the minimum specification,
atraaw00000430
there might be an oil pump malfunction, oil
strainer clogging, oil shortage, or excess of
each oil clearance. Repair or replace if necessary.
Note
• The oil pressure can vary with oil viscosity and temperature.
Oil pressure (reference value) [oil temperature: 100 °C {212 °F}]

103 kPa {1.1 kgf/cm2, 15 psi}/ min [1,500 rpm]

14. Remove the drive belt. (See 01-10B-4 DRIVE BELT REMOVAL/INSTALLATION[AJ (3.0L Duratec)].)
15. Remove the A/C compressor with the pipes still connected and position it out of the way. (See 07-11-12 A/C
COMPRESSOR REMOVAL/INSTALLATION [AJ (3.0L Duratec)].)
16. Remove the SSTs.
17. Install the oil pressure switch.
Tightening torque
14—18 N·m {1.5—1.8 kgf·m, 11—13 ft·lbf}
18. Install the A/C compressor. (See 07-11-12 A/C COMPRESSOR REMOVAL/INSTALLATION [AJ (3.0L
Duratec)].)
19. Install the drive belt. (See 01-10B-4 DRIVE BELT REMOVAL/INSTALLATION[AJ (3.0L Duratec)].)
End Of Sie
WM: OIL FILTER
01-11B–3
OIL FILTER REPLACEMENT[AJ (3.0L Duratec)]
id0111a2800700
Warning
Caution

2. Remove the oil filter using a filter wrench.
3. Use a clean rag to wipe off the mounting surface.
4. Apply clean engine oil to the O-ring of a new oil
filter.
5. Install the oil filter until the O-ring contacts the
sealing surface.
6. Tighten the oil filter 3/4 turns by hand.
7. Start the engine and confirm that there is no oil FILTER WRENCH
leakage.
• If there is oil leakage, repair or replace the
applicable part.
8. Inspect the oil level. (See 01-11B-2 ENGINE OIL
atraaw00000436
LEVEL INSPECTION[AJ (3.0L Duratec)].)
End Of Sie
OIL COOLER REMOVAL/INSTALLATION[AJ (3.0L Duratec)]
WM: OIL COOLER
id0111a2800800
Warning
Caution

4. Remove the oil pan drain plug and drain the
engine oil. (See 01-11B-2 ENGINE OIL
REPLACEMENT[AJ (3.0L Duratec)].)
atraaw00000437
01-11B–4
5. Remove the oil filter. (See 01-11B-4 OIL FILTER
01
atraaw00000438
6. Disconnect the water hoses at the oil cooler.
atraaw00000439
7. Remove the oil cooler.

9. Refill with the specified type and amount of the
engine oil. (See 01-11B-2 ENGINE OIL
REPLACEMENT[AJ (3.0L Duratec)].) 55—60 N·m {5.7—6.1 kgf·m,
10. Refill the engine coolant. (See 01-12B-5 ENGINE 41—44 ft·lbf}
COOLANT REPLACEMENT[AJ (3.0L Duratec)].)
12. Start the engine and confirm that there is no oil or
coolant leakage.
• If there is oil or coolant leakage, repair or
replace the applicable part.
atraaw00001581
End Of Sie
OIL PAN REMOVAL/INSTALLATION[AJ (3.0L Duratec)]
WM: OIL PAN
id0111a2800200
Warning
Caution
01-11B–5
Removal
3. Remove the front pipe. (See 01-15B-4 FRONT PIPE REMOVAL/INSTALLATION[AJ (3.0L Duratec)].)
4. Drain the engine oil. (See 01-11B-2 ENGINE OIL
Caution
• Replace the oil pan drain plug if
necessary. 22—30 N·m {2.3—3.0 kgf·m,
17—22 ft·lbf}
atraaw00003292
5. Remove the bolts and oil pan.
atraaw00000426
Installation
Caution
the sealing surfaces. These tools cause scratches and gouges which create leakage paths. Use a
plastic scraping tool to remove all traces of the gasket.
1. Clean all sealing surfaces on the engine and the oil pan.
2. Position a new gasket on the oil pan.
Note
• The oil pan must be installed and the bolts tightened within 6 min of sealant application.
3. Apply a 10 mm {0.39 in} diameter dot of silicone

10 mm {0.39 in}
sealant to the areas indicated.
4. Position the oil pan and hand-tighten the oil pan
bolts and stud bolts.
atraaw00000427
01-11B–6
5. Tighten the oil pan to transaxle bolts.
38—57 N·m {3.9—5.8 kgf·m,
29—42 ft·lbf}
01
atraaw00000428
6. Tighten the oil pan bolts in the order shown in the

figure. 1 2 3 4 5
7. Install the front pipe. (See 01-15B-4 FRONT PIPE
REMOVAL/INSTALLATION[AJ (3.0L Duratec)].) 6
8. Refill with the specified type and amount of the
engine oil. (See 01-11B-2 ENGINE OIL 20—30 N·m {2.1—3.0 kgf·m,
15—22 ft·lbf}
REPLACEMENT[AJ (3.0L Duratec)].) 15
9. Connect the negative battery cable. 10
10. Start the engine and confirm that there is no oil 12
leakage. 14 7
• If there is oil leakage, repair or replace the 13 11 9 8
applicable part.
atraaw00001582
End Of Sie
OIL PUMP REMOVAL/INSTALLATION[AJ (3.0L Duratec)]
WM: OIL PUMP
id0111a2800600
Removal
2. Remove the timing drive component. (See 01-10B-15 TIMING CHAIN REMOVAL/INSTALLATION[AJ (3.0L
Duratec)].)
3. Remove the oil strainer. (See 01-11B-8 OIL STRAINER REMOVAL/INSTALLATION[AJ (3.0L Duratec)].)
4. Remove the crankshaft pulley lock bolt and
crankshaft sprocket.
atraaw00000432
5. Remove the bolts in the order show in the figure

and remove the oil pump. 4
2
3 1
atraaw00000433
01-11B–7
Installation
1. Position the oil pump, and tighten the bolts in the
order indicated shown in the figure. 1 4
8—12 N·m {82—122
2 3
atraaw00000434
2. Install the crankshaft sprocket.

3. Install the oil strainer. (See 01-11B-8 OIL
STRAINER REMOVAL/INSTALLATION[AJ (3.0L
Duratec)].)
4. Install the timing drive component. (See 01-10B-
15 TIMING CHAIN REMOVAL/INSTALLATION[AJ
(3.0L Duratec)].)
5. Install the oil pan. (See 01-11B-5 OIL PAN
6. Inspect the oil pressure. (See 01-11B-3 OIL
PRESSURE INSPECTION[AJ (3.0L Duratec)].)
End Of Sie
WM: OIL STRAINER atraaw00000435
OIL STRAINER REMOVAL/INSTALLATION[AJ (3.0L Duratec)]

id0111a2801100
Removal
2. Remove the nuts, bolts, and oil strainer.
atraaw00000447
Installation
1. Install a new O-ring.
atraaw00000448
01-11B–8
2. Install the oil strainer.
(1) Position the oil strainer.
23
1
01
8—12 N·m {82—122
kgf·cm, 71—106 in·lbf} 2
atraaw00000449
(3) Tighten the nuts to 15 N·m {153 kgf·cm, 133

in·lbf}, then tighten another 45° using the
SST.
3. Install the oil pan. (See 01-11B-5 OIL PAN
End Of Sie
49 D032 316
atraaw00000450
01-11B–9
COOLING SYSTEM [L3]
01-12A COOLING SYSTEM [L3]

COOLING SYSTEM LOCATION COOLING SYSTEM CAP
INDEX[L3] . . . . . . . . . . . . . . . . . . . . . . . 01-12A–1 INSPECTION[L3] . . . . . . . . . . . . . . . . . . 01-12A–6
COOLING SYSTEM SERVICE COOLANT RESERVE TANK
WARNINGS[L3]. . . . . . . . . . . . . . . . . . . 01-12A–2 REMOVAL/INSTALLATION[L3] . . . . . . . 01-12A–6
ENGINE COOLANT LEVEL RADIATOR REMOVAL/INSTALLATION
INSPECTION[L3] . . . . . . . . . . . . . . . . . 01-12A–2 [L3] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-12A–7
ENGINE COOLANT PROTECTION THERMOSTAT 01
INSPECTION[L3] . . . . . . . . . . . . . . . . . 01-12A–3 REMOVAL/INSTALLATION[L3] . . . . . . . 01-12A–9
ENGINE COOLANT REPLACEMENT THERMOSTAT INSPECTION[L3] . . . . . . 01-12A–10
[L3] . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-12A–4 WATER PUMP
ENGINE COOLANT LEAKAGE REMOVAL/INSTALLATION[L3] . . . . . . . 01-12A–10
INSPECTION[L3] . . . . . . . . . . . . . . . . . 01-12A–5 FAN MOTOR
REMOVAL/INSTALLATION[L3] . . . . . . . 01-12A–12
FAN MOTOR INSPECTION[L3] . . . . . . . . 01-12A–14
End of Toc
COOLING SYSTEM LOCATION INDEX[L3]
WM: COOLING SYSTEM
id0112a1800100
7
5
6
3
2
1
atraaw00000451
1 Cooling system cap 4 Thermostat

(See 01-12A-6 COOLING SYSTEM CAP (See 01-12A-9 THERMOSTAT REMOVAL/
2 Coolant reserve tank (See 01-12A-10 THERMOSTAT INSPECTION[L3].)
(See 01-12A-2 ENGINE COOLANT LEVEL 5 Water pump
INSPECTION[L3].) (See 01-12A-10 WATER PUMP REMOVAL/
(See 01-12A-6 COOLANT RESERVE TANK INSTALLATION[L3].)
REMOVAL/INSTALLATION[L3].) 6 Cooling fan motor No.1
3 Radiator (See 01-12A-12 FAN MOTOR REMOVAL/
(See 01-12A-3 ENGINE COOLANT PROTECTION INSTALLATION[L3].)
INSPECTION[L3].) (See 01-12A-14 FAN MOTOR INSPECTION[L3].)
(See 01-12A-4 ENGINE COOLANT 7 Cooling fan motor No.2
REPLACEMENT[L3].) (See 01-12A-12 FAN MOTOR REMOVAL/
(See 01-12A-5 ENGINE COOLANT LEAKAGE INSTALLATION[L3].)
INSPECTION[L3].) (See 01-12A-14 FAN MOTOR INSPECTION[L3].)
(See 01-12A-7 RADIATOR REMOVAL/
INSTALLATION[L3].)
End Of Sie
01-12A–1
COOLING SYSTEM [L3]
COOLING SYSTEM SERVICE WARNINGS[L3]
id0112a1800200
Warning
• Never remove the cooling system cap or loosen the radiator drain plug while the engine is
running, or when the engine and radiator are hot. Scalding engine coolant and steam may shoot
out and cause serious injury. It may also damage the engine and cooling system.
• Turn off the engine and wait until it is cool. Even then, be very careful when removing the cap.
Wrap a thick cloth around it and slowly turn it counterclockwise to the first stop. Step back while
the pressure escapes.
• When you are sure all the pressure is gone, press down on the cap using the cloth, turn it, and
remove it.
End Of Sie
ENGINE COOLANT LEVEL INSPECTION[L3]
WM: ENGINE COOLANT
id0112a1800300
Warning
remove it.
Note
• If the “FL22” mark is shown on or near the cooling system cap, use FL22 type engine coolant.
• FL22 type engine coolant is shipped as a
diluted solution (55% coolant, 45% water).
Use the solution as is when replacing
coolant.
atraaw00000476
1. Verify that the engine coolant level in the coolant

COOLING SYSTEM CAP
reserve tank is between the F and L marks.
• If the engine coolant level is below the L mark,
add engine coolant.
End Of Sie
COOLANT
RESERVE
TANK
atraaw00000453
01-12A–2
COOLING SYSTEM [L3]
ENGINE COOLANT PROTECTION INSPECTION[L3]
id0112a1800400
1. Measure the engine coolant temperature and specific gravity using a thermometer and a hydrometer.
Caution
• Use engine coolant at a concentration that meets the environmental conditions in which the
vehicle is driven, otherwise engine damage could occur.
• The engine has aluminum parts and must be protected by an ethylene-glycol-based coolant to
prevent corrosion and freezing.
• Do not use coolants containing Alcohol, Methanol, Borate or Silicate. These coolants could 01
damage the cooling system.
• Use only soft (demineralized) water in the coolant mixture. Water that contains minerals will cut
down on the coolant’s effectiveness.
• Engine coolant damages paint. If engine coolant does get on a painted surface, rinse it off quickly.
Note
coolant.
atraaw00000476
2. Determine the engine coolant protection level by

SPECIFIC COOLANT PROTECTION
referring to the graph shown in the figure. (EXCEPT FL22 TYPE ENGINE COOLANT)
GRAVITY
• If the engine coolant protection level is not 1.10
correct, add water or engine coolant.
End Of Sie 1.09
1.08
1.07 55%
1.06
45%
1.05
35%
1.04
1.03
1.02
1.01
1.00
0 5 10 15 20 25 30 35 40 45 50
{32} {41} {50} {59} {68} {77} {86} {95} {104} {113} {122}
COOLANT TEMPERATURE °C {°F}

atraaw00000455
01-12A–3
COOLING SYSTEM [L3]
ENGINE COOLANT REPLACEMENT[L3]
id0112a1800600
Warning
remove it.
Caution
• Do not use coolants containing Alcohol, Methanol, Borate or Silicate. These coolants could
Note
coolant.
Engine coolant capacity (approx. quantity)

7.5 L {7.9 US qt, 6.6 Imp qt}
1. Remove the cooling system cap.

2. Remove the splash shield (LH).
atraaw00000476
3. Loosen the radiator drain plug and drain the

engine coolant into a container. COOLING SYSTEM CAP
4. Flush the cooling system with water until all traces
of color are gone.
5. Let the system drain completely. RADIATOR DRAIN PLUG
6. Tighten the radiator drain plug.
7. Referring to the following chart, select the correct
volume percentage of the water and engine
coolant.
atraaw00000458
Antifreeze solution mixture percentage (Except FL22 type engine coolant)

Volume percentage (%)
Engine coolant protection Gravity at 20 °C {68 °F}
Water Coolant
Above -16 °C {3 °F} 65 35 1.057
Above -26 °C {-15 °F} 55 45 1.072
Above -40 °C {-40 °F} 45 55 1.086
8. Refill the engine coolant into the coolant reserve tank up to the F mark on the tank.
01-12A–4
COOLING SYSTEM [L3]
9. Install the cooling system cap.
Caution
• If the water temperature gauge rises too high, stop the engine and decrease the engine coolant
temperature to prevent overheating. Then, verify the malfunctioning part and repair or replace it.
• If the engine coolant level in the coolant reserve tank is below the L mark during engine coolant air
bleeding operation, stop the engine, and after the engine coolant temperature decreases, add
engine coolant. Then, resume the engine coolant air bleeding operation.
10. Start the engine and warm up the engine by idling.

01
11. After the engine warms up, perform the following steps. At this time, be careful of the coolant temperature to
prevent overheating.
Note
• If the accelerator pedal is depressed continuously for a specified time, the engine speed may decrease to
the idle speed. This is due to the fuel cut control operation, which prevents overheating, and it does not
indicate a malfunction.
(1) Run the engine at approx. 4,000 rpm for 1 min.

(2) Run the engine at idle for 1 min.
(3) Repeat steps (1), (2) approx. 2 times.
(4) Turn the heater on and verify that warm air flows from the ventilation grille.
12. Stop the engine, and inspect the engine coolant level after the engine coolant temperature decreases. If it is
low, repeat steps 8—11.
13. Inspect for engine coolant leakage. (See 01-12A-5 ENGINE COOLANT LEAKAGE INSPECTION[L3].)
14. Install the splash shield (LH).
End Of Sie
ENGINE COOLANT LEAKAGE INSPECTION[L3]
id0112a1800500
Warning
remove it.
1. Inspect the engine coolant level. (See 01-12A-2 ENGINE COOLANT LEVEL INSPECTION[L3].)
3. Install the SST and a radiator cap tester to the
coolant reserve tank filler port.
4. Apply pressure using the radiator cap tester.
49 9200 145
Caution
• Applying more than 122.6 kPa {1.25 kgf/
cm2, 17.8 psi} can damage the hoses,
fittings, and other components, and
cause leakage.
Pressure
122.6 kPa {1.25 kgf/cm2, 17.8 psi} [1 min] atraaw00000456
5. When pressurizing the cooling system, verify that the pressure is maintained.
• If the gauge needle drops, it may indicate water leakage. Repair or replace the applicable part.
End Of Sie
WM: COOLING SYSTEM CAP
01-12A–5
COOLING SYSTEM [L3]
COOLING SYSTEM CAP INSPECTION[L3]
id0112a1801500
Warning
• When you’re sure all the pressure is gone, press down on the cap using the cloth, turn it, and
remove it.
1. Clean the cooling system cap and the sealed part.

2. Inspect the cooling system cap for cracks or everted seal.
• If there is any malfunction, replace the cooling system cap.
3. Attach the cooling system cap to the SST and a
radiator cap tester.
49 9200 145
4. Hold the cooling system cap downward and apply
pressure gradually. Verify that the pressure is held
stable for 10 s.
• If the pressure is not held stable, replace the
cooling system cap.
Cooling system cap valve opening pressure

93.2—122.6 kPa {0.95—1.25 kgf/cm2, 13.5— COOLING SYSTEM CAP
17.8 psi}
atraaw00000466
End Of Sie
COOLANT RESERVE TANK REMOVAL/INSTALLATION[L3]
WM: COOLANT RESERVE TANK
id0112a1801000
Warning
remove it.

2. Drain the engine coolant until the coolant reserve tank becomes empty. (See 01-12A-4 ENGINE COOLANT
REPLACEMENT[L3].)
5. Refill the engine coolant. (See 01-12A-4 ENGINE COOLANT REPLACEMENT[L3].)
6. Inspect for engine coolant leakage. (See 01-12A-
5 ENGINE COOLANT LEAKAGE
INSPECTION[L3].). 7.8—10.8
{79.6—110.1,
1 Hose 69.1—95.5}
2
2 Coolant reserve tank
3 Hose
End Of Sie
WM: RADIATOR
7.8—10.8
{79.6—110.1,
69.1—95.5}
3 N·m {kgf·cm, in·lbf}

1
atraaw00002345
01-12A–6
COOLING SYSTEM [L3]
RADIATOR REMOVAL/INSTALLATION[L3]
id0112a1801400
Warning
the pressure escapes. 01
remove it.

3. Drain the engine coolant. (See 01-12A-4 ENGINE COOLANT REPLACEMENT[L3].)
4. Remove the front bumper. (See 09-10-1 FRONT BUMPER REMOVAL/INSTALLATION.)
8. Inspect for engine coolant leakage. (See 01-12A-5 ENGINE COOLANT LEAKAGE INSPECTION[L3].)
01-12A–7
COOLING SYSTEM [L3]
9. Inspect the ATF level. (See 05-17A-8 AUTOMATIC TRANSAXLE FLUID (ATF) INSPECTION[GF4AX-EL].)
4 4
7.8—10.8
{79.6—110.1, 69.1—95.5}
9 E 7.8—10.8
A {79.6—110.1,
F 69.1—95.5}
B
10
C
11
7.8—10.8 4
{79.6—110.1, 69.1—95.5} 2
1
3
7.8—10.8
{79.6—110.1, 69.1—95.5}
5 1
D
7
7
A
E
B
F
8 6
6
atraaw00002330
1 Radiator bracket 7 Coolant reserve tank hose

2 Hood latch 8 Radiator lower hose
(See 01-12A-9 Hood Latch Removal Note.) 9 Radiator and cooling fan component
3 Center support (See 01-12A-9 Radiator and Cooling Fan
(See 01-12A-9 Center Support Removal Note.) Component Removal Note.)
4 Connector 10 Cooling fan component
5 Radiator upper hose 11 Radiator
6 ATF oil cooler hose
01-12A–8
COOLING SYSTEM [L3]
Hood Latch Removal Note
1. Remove the hood latch with the cable still 8.0—11.0 N·m {81.6—112.1
connected. Position the hood latch so that it is out kgf·cm, 70.9—97.2 in·lbf}
of the way.
01
atraaw00002331
Center Support Removal Note

1. Remove the two bolts and the center support.
7.9—10.7 N·m {80.6—109.1

atraaw00002332
Radiator and Cooling Fan Component Removal Note

1. Remove the radiator and cooling fan component from above the engine compartment.
End Of Sie
THERMOSTAT REMOVAL/INSTALLATION[L3]
WM: THERMOSTAT
id0112a1801200
Warning
remove it.

6. Remove the P/S oil pump with hose and pipe still connected. Position the P/S oil pump out of the way. (See 06-
14-37 POWER STEERING OIL PUMP REMOVAL/INSTALLATION[L3].)
01-12A–9
COOLING SYSTEM [L3]
INSPECTION[L3].).
1 Water hose
2 Lower radiator hose
3 Thermostat component
4 Gasket
8.0—11.5
End Of Sie 3 {82—117,
71—101}
R 4
8.0—11.5
{82—117,
71—101}
2 1
atraaw00000462
THERMOSTAT INSPECTION[L3]
id0112a1801300
1. Inspect the thermostat for the following.
Warning
• During inspection, the thermostat and water are extremely hot and can cause severe burns. Do not
touch the thermostat and water.
• The valve should not open under normal temperature.

• Opening temperature and valve lift
— If there is a malfunction, replace the thermostat.
Thermostat initial-opening temperature

80—84 °C {176—183 °F}
Thermostat full-open temperature

97 °C {207 °F}
Thermostat full-open lift

More than 8.0 mm {0.31 in}
End Of Sie
WATER PUMP REMOVAL/INSTALLATION[L3]
WM: WATER PUMP
id0112a1800700
Warning
remove it.

01-12A–10
COOLING SYSTEM [L3]
INSPECTION[L3].).
1 Water pump pulley
2 Water pump
3 O-ring
(See 01-12A-11 O-ring Installation Note.) 01
R
3
2
17—23
{1.8—2.3, 8.0—11.5 N·m
13—16} {82—117 kgf·cm,
71—101 in·lbf}
atraaw00000459
O-ring Installation Note

1. Apply engine coolant to a new O-ring.
2. Install the O-ring.
End Of Sie
WM: COOLING FAN MOTOR
01-12A–11
COOLING SYSTEM [L3]
FAN MOTOR REMOVAL/INSTALLATION[L3]
id0112a1801600
Warning
• Remove and install all parts when the engine is cold, otherwise they can cause severe burns or
serious injury.

6. Inspect the ATF level. (See 05-17A-8 AUTOMATIC TRANSAXLE FLUID (ATF) INSPECTION[GF4AX-EL].)
5 5
7.8—10.8
{79.6—110.1, 69.1—95.5}
3.9—4.9 12
{40—49, 35—42}
10 11
8
7.8—10.8
{79.6—110.1,
69.1—95.5}
2.9—3.9
{30—39, 27—33} 9
7.8—10.8 5
{79.6—110.1, 69.1—95.5} 3
1
4
2
A 7.8—10.8
{79.6—110.1, 69.1—95.5}
A 7
7.8—10.8
{79.6—110.1,
69.1—95.5}
7.8—10.8 {79.6—110.1, 69.1—95.5} N·m {kgf·cm, in·lbf}
atraaw00002333
1 Radiator bracket 4 Center support

2 Radiator seal plate (See 01-12A-13 Center Support Removal Note.)
3 Hood latch 5 Connector
(see 01-12A-13 Hood Latch Removal Note.)
01-12A–12
COOLING SYSTEM [L3]
6 P/S cooling pipe 9 Cooling fan No.1
(See 01-12A-13 P/S Cooling Pipe Removal Note.) 10 Cooling fan No.2
7 ATF oil cooler hose 11 Cooling fan motor No.1
8 Cooling fan component 12 Cooling fan motor No.2
(See 01-12A-13 Cooling Fan Component Removal
Note.)
Hood Latch Removal Note 01

of the way.
atraaw00002334

7.9—10.7 N·m {80.6—109.1

atraaw00002335
P/S Cooling Pipe Removal Note

1. Remove the P/S cooling pipe with the hoses still connected.
Cooling Fan Component Removal Note

1. Move the condenser toward the front of vehicle to make space.
2. Move the radiator toward the front of vehicle to make space.
3. Remove the cooling fan component from above the engine compartment.
End Of Sie
01-12A–13
COOLING SYSTEM [L3]
FAN MOTOR INSPECTION[L3]
id0112a1800900
Part inspection
1. Verify that the battery is fully charged. (See 01-17A-2 BATTERY INSPECTION[L3].)
2. Disconnect the cooling fan motor connector.
3. Install a tester and battery to the cooling fan
motor connector as shown in the figure. B
4. Verify that each fan motors operate smoothly at COOLING FAN
the standard current. MOTOR
• If there is any malfunction, replace the NO.1, NO.2
applicable part. CONNECTOR
A
Cooling fan motor standard current
No.1: 3.6—6.6 A
COOLING FAN MOTOR NO.1, NO.2 CONNECTOR
No.2: 7.7—10.7 A
NO.1 NO.2
End Of Sie
A B B A
atraaw00000460
01-12A–14
COOLING SYSTEM [AJ (3.0L Duratec)]
01-12B COOLING SYSTEM [AJ (3.0L Duratec)]

COOLING SYSTEM LOCATION INDEX RADIATOR
COOLING SYSTEM SERVICE [AJ (3.0L Duratec)] . . . . . . . . . . . . . . . . 01-12B–8
WARNINGS[AJ (3.0L Duratec)] . . . . . . 01-12B–3 THERMOSTAT
ENGINE COOLANT LEVEL REMOVAL/INSTALLATION
INSPECTION[AJ (3.0L Duratec)] . . . . . 01-12B–3 [AJ (3.0L Duratec)] . . . . . . . . . . . . . . . . 01-12B–10
ENGINE COOLANT PROTECTION THERMOSTAT INSPECTION 01
INSPECTION[AJ (3.0L Duratec)] . . . . . 01-12B–4 [AJ (3.0L Duratec)] . . . . . . . . . . . . . . . . 01-12B–11
ENGINE COOLANT REPLACEMENT WATER PUMP
ENGINE COOLANT LEAKAGE [AJ (3.0L Duratec)] . . . . . . . . . . . . . . . . 01-12B–11
INSPECTION[AJ (3.0L Duratec)] . . . . . 01-12B–6 COOLING FAN COMPONENT
COOLING SYSTEM CAP INSPECTION REMOVAL/INSTALLATION
COOLANT RESERVE TANK FAN MOTOR INSPECTION
[AJ (3.0L Duratec)] . . . . . . . . . . . . . . . . 01-12B–7
End of Toc
WM: COOLING SYSTEM
01-12B–1
COOLING SYSTEM LOCATION INDEX[AJ (3.0L Duratec)]
id0112a2800100
A
5
B
2
1
3 6 7
atraaw00000470
1 Cooling system cap 4 Thermostat

(See 01-12B-7 COOLING SYSTEM CAP (See 01-12B-10 THERMOSTAT REMOVAL/
INSPECTION[AJ (3.0L Duratec)].) INSTALLATION[AJ (3.0L Duratec)].)
2 Coolant reserve tank (See 01-12B-11 THERMOSTAT INSPECTION[AJ
(See 01-12B-3 ENGINE COOLANT LEVEL (3.0L Duratec)].)
INSPECTION[AJ (3.0L Duratec)].) 5 Water pump
(See 01-12B-7 COOLANT RESERVE TANK (See 01-12B-11 WATER PUMP REMOVAL/
REMOVAL/INSTALLATION[AJ (3.0L Duratec)].) INSTALLATION[AJ (3.0L Duratec)].)
3 Radiator 6 Cooling fan motor No.1
(See 01-12B-4 ENGINE COOLANT PROTECTION (See 01-12B-12 COOLING FAN COMPONENT
INSPECTION[AJ (3.0L Duratec)].) REMOVAL/INSTALLATION[AJ (3.0L Duratec)].)
(See 01-12B-5 ENGINE COOLANT (See 01-12B-14 FAN MOTOR INSPECTION[AJ
REPLACEMENT[AJ (3.0L Duratec)].) (3.0L Duratec)].)
(See 01-12B-6 ENGINE COOLANT LEAKAGE 7 Cooling fan motor No.2
INSPECTION[AJ (3.0L Duratec)].) (See 01-12B-12 COOLING FAN COMPONENT
(See 01-12B-8 RADIATOR REMOVAL/ REMOVAL/INSTALLATION[AJ (3.0L Duratec)].)
INSTALLATION[AJ (3.0L Duratec)].) (See 01-12B-14 FAN MOTOR INSPECTION[AJ
(3.0L Duratec)].)
End Of Sie
01-12B–2
COOLING SYSTEM SERVICE WARNINGS[AJ (3.0L Duratec)]
id0112a2800200
Warning
remove it.
End Of Sie
ENGINE COOLANT LEVEL INSPECTION[AJ (3.0L Duratec)]
WM: ENGINE COOLANT
id0112a2800300
Warning
remove it.
Note
coolant.
atraaw00000476
1. Verify that the engine coolant level in the coolant

COOLING SYSTEM CAP
reserve tank is between the F and L marks.
• If the engine coolant level is below the L mark,
add engine coolant.
End Of Sie
COOLANT
RESERVE
TANK
atraaw00000472
01-12B–3
ENGINE COOLANT PROTECTION INSPECTION[AJ (3.0L Duratec)]
id0112a2800400
1. Measure the coolant temperature and specific gravity using a thermometer and a hydrometer.
Caution
Note
coolant.
atraaw00000476
2. Determine the engine coolant protection level by

SPECIFIC COOLANT PROTECTION
referring to the graph shown in the figure. GRAVITY (EXCEPT FL22 TYPE ENGINE COOLANT)
• If the engine coolant protection level is not
1.10
correct, add water or engine coolant.
End Of Sie 1.09
1.08
1.07 55%
1.06
45%
1.05
35%
1.04
1.03
1.02
1.01
1.00
0 5 10 15 20 25 30 35 40 45 50
{32} {41} {50} {59} {68} {77} {86} {95} {104} {113} {122}
COOLANT TEMPERATURE °C {°F}

atraaw00000474
01-12B–4
ENGINE COOLANT REPLACEMENT[AJ (3.0L Duratec)]
id0112a2800600
Warning
remove it.
Caution
Note
coolant.
Engine coolant capacity (approx. quantity)

10.0 L {10.6 US qt, 8.80 Imp qt}

atraaw00000476
3. Loosen the radiator drain plug and drain the

engine coolant into a container.
4. Flush the cooling system with water until all traces
of color are gone.
5. Let the system drain completely.
6. Tighten the radiator drain plug.
7. Referring to the following chart, select the correct
volume percentage of the water and engine
coolant.
atraaw00000477
Antifreeze solution mixture percentage (Except FL22 type engine coolant)

Volume percentage (%)
Engine coolant protection Gravity at 20 °C {68 °F}
Water Coolant
Above -16 °C {3 °F} 65 35 1.057
Above -26 °C {-15 °F} 55 45 1.072
Above -40 °C {-40 °F} 45 55 1.086
8. Refill the engine coolant into the coolant reserve tank up to the F mark on the tank.
01-12B–5
9. Install the cooling system cap.
Caution
• If the water temperature gauge rises too high, stop the engine and decrease the engine coolant
temperature to prevent overheating. Then, verify the malfunctioning part and repair or replace it.
• If the engine coolant level in the coolant reserve tank is below the L mark during engine coolant air
bleeding operation, stop the engine, and after the engine coolant temperature decreases, add
engine coolant. Then, resume the engine coolant air bleeding operation.
10. Start the engine and warm up the engine by idling.

11. After the engine warms up, perform the following steps. At this time, be careful of the coolant temperature to
prevent overheating.
(1) Run the engine at approx. 4,000 rpm for 1 min.
(2) Run the engine at idle for 1 min.
(3) Repeat steps (1), (2) approx. 2 times.
(4) Turn the heater on and verify that warm air flows from the ventilation grille.
12. Stop the engine, and inspect the engine coolant level after the engine coolant temperature decreases. If it is
low, repeat steps 8—11.
13. Inspect for engine coolant leakage. (See 01-12B-6 ENGINE COOLANT LEAKAGE INSPECTION[AJ (3.0L
Duratec)].)
End Of Sie
ENGINE COOLANT LEAKAGE INSPECTION[AJ (3.0L Duratec)]
id0112a2800500
Warning
remove it.
1. Inspect the engine coolant level. (See 01-12B-3 ENGINE COOLANT LEVEL INSPECTION[AJ (3.0L Duratec)].)
3. Install the SST and a radiator cap tester to the
coolant reserve tank filler port.
4. Apply pressure using the radiator cap tester.
49 9200 145
Caution
• Applying more than 122.6 kPa {1.25 kgf/
cm2, 17.8 psi} can damage the hoses,
fittings, and other components, and
cause leakage.
Pressure
122.6 kPa {1.25 kgf/cm2, 17.8 psi} [1 min] atraaw00000475
5. When pressurizing the cooling system, verify that the pressure is maintained.
• If the gauge needle drops, it may indicate water leakage. Repair or replace the applicable part.
End Of Sie
WM: COOLING SYSTEM CAP
01-12B–6
COOLING SYSTEM CAP INSPECTION[AJ (3.0L Duratec)]
id0112a2801500
Warning
• When you’re sure all the pressure is gone, press down on the cap using the cloth, turn it, and
remove it.
1. Clean the cooling system cap and the sealed part.

2. Inspect the cooling system cap for cracks or everted seal.
• If there is any malfunction, replace the cooling system cap.
3. Attach the cooling system cap to the SST and a
radiator cap tester.
49 9200 145
4. Hold the cooling system cap downward and apply
pressure gradually. Verify that the pressure is held
stable for 10 s.
• If the pressure is not held stable, replace the
cooling system cap.
Cooling system cap valve opening pressure

93.2—122.6 kPa {0.95—1.25 kgf/cm2, 13.5— COOLING SYSTEM CAP
17.8 psi}
atraaw00000486
End Of Sie
COOLANT RESERVE TANK REMOVAL/INSTALLATION[AJ (3.0L Duratec)]
WM: COOLANT RESERVE TANK
id0112a2801000
Warning
remove it.

2. Drain the engine coolant until the coolant reserve tank becomes empty. (See 01-12B-5 ENGINE COOLANT
5. Refill the engine coolant. (See 01-12B-5 ENGINE COOLANT REPLACEMENT[AJ (3.0L Duratec)].)
6. Inspect for engine coolant leakage. (See 01-12B-
6 ENGINE COOLANT LEAKAGE 7.8—10.8
INSPECTION[AJ (3.0L Duratec)].). {79.6—110.1,
69.1—95.5}
1 Hose 2
2 Coolant reserve tank
3 Hose
End Of Sie
WM: RADIATOR
7.8—10.8
{79.6—110.1,
69.1—95.5}

1
atraaw00002336
01-12B–7
RADIATOR REMOVAL/INSTALLATION[AJ (3.0L Duratec)]
id0112a2801400
Warning
remove it.

8. Inspect for engine coolant leakage. (See 01-12B-6 ENGINE COOLANT LEAKAGE INSPECTION[AJ (3.0L
Duratec)].)
01-12B–8
9. Inspect the ATF level. (See 05-17B-5 AUTOMATIC TRANSAXLE FLUID (ATF) INSPECTION[LA4AX-EL
(CD4E)].)
7.8—10.8
{79.6—110.1,
E
69.1—95.5}
01
F
A
10
4
B
C
11 D
7.8—10.8
{79.6—110.1,
69.1—95.5}
1 2
3
7.8—10.8
{79.6—110.1,
69.1—95.5}
7
1
E
D
8
F
A
B
6
7
6
A
B
C
A
D
5
atraaw00002337
1 Radiator bracket 7 Coolant reserve tank hose

2 Hood latch 8 Radiator upper hose
(See 01-12B-10 Hood Latch Removal Note.) 9 Radiator and cooling fan component
3 Center support (See 01-12B-10 Radiator and Cooling Fan
(See 01-12B-10 Center Support Removal Note.) Component Removal Note.)
4 Connector 10 Cooling fan component
5 Radiator lower hose 11 Radiator
6 ATF oil cooler hose
01-12B–9
of the way.
atraaw00002338

7.9—10.7 N·m {80.6—109.1

atraaw00002339
Radiator and Cooling Fan Component Removal Note

1. Remove the radiator and cooling fan component from above the engine compartment.
End Of Sie
THERMOSTAT REMOVAL/INSTALLATION[AJ (3.0L Duratec)]
WM: THERMOSTAT
id0112a2801200
Warning
remove it.

6 ENGINE COOLANT LEAKAGE 1
INSPECTION[AJ (3.0L Duratec)].).
1 Upper radiator hose
2 Lower radiator hose
3 Thermostat cover 8.0—11.5 {82—117, 71—101}
4 O-ring 5
5 Thermostat
3 4 R
(See 01-12B-11 Thermostat Installation Note.)
atraaw00000481
01-12B–10
Thermostat Installation Note
1. Install the thermostat into the thermostat case
with the jiggle pin at the top.
End Of Sie JIGGLE PIN
01
atraaw00000482
THERMOSTAT INSPECTION[AJ (3.0L Duratec)]

id0112a2801300
1. Inspect the thermostat for the following.
Warning
• During inspection, the thermostat and water are extremely hot and can cause severe burns. Do not
touch the thermostat and water.
• The valve should not open under normal temperature.

• Opening temperature and valve lift
— If there is a malfunction, replace the thermostat.
Thermostat initial-opening temperature

84—88 °C {184—190 °F}
Thermostat full-open temperature

99 °C {210 °F}
Thermostat full-open lift

More than 7.3 mm {0.29 in}
End Of Sie
WATER PUMP REMOVAL/INSTALLATION[AJ (3.0L Duratec)]
WM: WATER PUMP
id0112a2800700
Warning
remove it.
1. Remove the battery. (See 01-17B-2 BATTERY REMOVAL/INSTALLATION[AJ (3.0L Duratec)].)

4. Remove the water pump drive pulley. (See 01-10B-22 CAMSHAFT (LH) REMOVAL/INSTALLATION[AJ (3.0L
Duratec)].)
01-12B–11
INSPECTION[AJ (3.0L Duratec)].).
4 3
1 Thermostat case component
2 Oil cooler water hose
3 Water outlet hose
4 Water pump
(See 01-12B-12 Water Pump Installation Note.)
R
2
10 {102, 89}
+85° —95°
1
atraaw00000478
Water Pump Installation Note

1. Tighten the bolts to the specified tightening torque, then tighten them further 85—95 °.
End Of Sie
COOLING FAN COMPONENT REMOVAL/INSTALLATION[AJ (3.0L Duratec)]
WM: COOLING FAN MOTOR
id0112a2802500
Warning
serious injury.

01-12B–12
6. Inspect the ATF level. (See 05-17B-5 AUTOMATIC TRANSAXLE FLUID (ATF) INSPECTION[LA4AX-EL
(CD4E)].)
5
7.8—10.8
{79.6—110.1,
69.1—95.5}
9
01
7.8—10.8
{79.6—110.1, 3
69.1—95.5}
1
4
2
A 7.8—10.8
{79.6—110.1,
69.1—95.5}
1
A 8
7.8—10.8
{79.6—110.1,
69.1—95.5} 6
7.8—10.8 {79.6—110.1, 69.1—95.5} N·m {kgf·cm, in·lbf}
atraaw00002340
1 Radiator bracket 6 P/S cooling pipe

2 Radiator seal plate (See 01-12B-14 P/S Cooling Pipe Removal Note.)
3 Hood latch 7 ATF oil cooler
(see 01-12B-14 Hood Latch Removal Note.) (See 01-12B-14 ATF Oil Cooler Removal Note.)
4 Center support 8 ATF oil cooler hose
(See 01-12B-14 Center Support Removal Note.) 9 Cooling fan component
5 Connector (See 01-12B-14 Cooling Fan Component Removal
Note.)
01-12B–13
of the way.
atraaw00002341

7.9—10.7 N·m {80.6—109.1

atraaw00002342
P/S Cooling Pipe Removal Note

1. Remove the P/S cooling pipe with the hoses still connected.
ATF Oil Cooler Removal Note

1. Remove the ATF oil cooler with the hoses still connected.
Cooling Fan Component Removal Note

1. Move the condenser toward the front of vehicle to make space.
2. Move the radiator toward the front of vehicle to make space.
3. Remove the cooling fan component from above the engine compartment.
End Of Sie
FAN MOTOR INSPECTION[AJ (3.0L Duratec)]
id0112a2800900
Part inspection
1. Verify that the battery is fully charged. (See 01-17B-2 BATTERY INSPECTION[AJ (3.0L Duratec)].)
2. Disconnect the cooling fan motor connector.
3. Install a tester and battery to the cooling fan
motor connector as shown in the figure. B
4. Verify that each fan motors operate smoothly at COOLING FAN
the standard current. MOTOR
• If there is any malfunction, replace the NO.1, NO.2
applicable part. CONNECTOR
A
Cooling fan motor No.1, No,2 standard current
Approx. 20 A
COOLING FAN MOTOR NO.1, NO.2 CONNECTOR
End Of Sie
A B
atraaw00001583
01-12B–14
INTAKE-AIR SYSTEM [L3]
01-13A INTAKE-AIR SYSTEM [L3]

INTAKE-AIR SYSTEM LOCATION THROTTLE BODY INSPECTION
INDEX[L3] . . . . . . . . . . . . . . . . . . . . . . . 01-13A–2 [L3] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-13A–7
INTAKE-AIR SYSTEM DIAGRAM VARIABLE INTAKE AIR SOLENOID
[L3] . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-13A–3 VALVE INSPECTION[L3] . . . . . . . . . . . . 01-13A–8
INTAKE AIR SYSTEM HOSE ROUTING VARIABLE TUMBLE SOLENOID
DIAGRAM[L3] . . . . . . . . . . . . . . . . . . . . 01-13A–4 VALVE INSPECTION[L3] . . . . . . . . . . . . 01-13A–9
INTAKE MANIFOLD VACUUM VARIABLE INTAKE AIR SHUTTER 01
INSPECTION[L3] . . . . . . . . . . . . . . . . . 01-13A–4 VALVE ACTUATOR INSPECTION
INTAKE-AIR SYSTEM [L3] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-13A–10
REMOVAL/INSTALLATION[L3] . . . . . . 01-13A–5 VARIABLE TUMBLE SHUTTER VALVE
AIR CLEANER ELEMENT INSPECTION ACTUATOR INSPECTION[L3] . . . . . . . . 01-13A–10
[L3] . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-13A–6 ACCELERATOR PEDAL
REMOVAL/INSTALLATION[L3] . . . . . . . 01-13A–10
End of Toc
WM: INTAKE-AIR SYSTEM
01-13A–1
INTAKE-AIR SYSTEM LOCATION INDEX[L3]
id0113a2801700
8
5
2
4 3
1
7
6
atraaw00001126
1 Intake manifold 4 Variable intake air solenoid valve

(See 01-13A-5 INTAKE-AIR SYSTEM REMOVAL/ (See 01-13A-5 INTAKE-AIR SYSTEM REMOVAL/
INSTALLATION[L3].) INSTALLATION[L3].)
(See 01-13A-4 INTAKE MANIFOLD VACUUM (See 01-13A-8 VARIABLE INTAKE AIR SOLENOID
INSPECTION[L3].) VALVE INSPECTION[L3].)
2 Air cleaner 5 Variable tumble solenoid valve
(See 01-13A-5 INTAKE-AIR SYSTEM REMOVAL/ (See 01-13A-5 INTAKE-AIR SYSTEM REMOVAL/
(See 01-13A-6 AIR CLEANER ELEMENT (See 01-13A-9 VARIABLE TUMBLE SOLENOID
INSPECTION[L3].) VALVE INSPECTION[L3].)
3 Throttle body 6 Variable intake air shutter valve actuator
(See 01-13A-5 INTAKE-AIR SYSTEM REMOVAL/ (See 01-13A-10 VARIABLE INTAKE AIR SHUTTER
INSTALLATION[L3].) VALVE ACTUATOR INSPECTION[L3].)
(See 01-13A-7 THROTTLE BODY 7 Variable tumble shutter valve actuator
INSPECTION[L3].) (See 01-13A-10 VARIABLE TUMBLE SHUTTER
VALVE ACTUATOR INSPECTION[L3].)
8 Accelerator pedal
(See 01-13A-10 ACCELERATOR PEDAL
End Of Sie
01-13A–2
INTAKE-AIR SYSTEM DIAGRAM[L3]
id0113a2801600
AIR CLEANER FRESH-AIR DUCT

VACUUM CHAMBER (RESONANCE CHAMBER)
INTAKE MANIFOLD RESONANCE CHAMBER
01
RESONANCE CHAMBER
THROTTLE BODY
VARIABLE TUMBLE SOLENOID VALVE
VARIABLE TUMBLE SHUTTER VARIABLE INTAKE AIR SOLENOID VALVE

VALVE ACTUATOR
VARIABLE INTAKE AIR SHUTTER VALVE ACTUATOR
: ATMOSPHERIC AIRFLOW
aesffw00000524
End Of Sie
01-13A–3
INTAKE AIR SYSTEM HOSE ROUTING DIAGRAM[L3]
id0113a2804100
PURGE SOLENOID VALVE
VARIABLE INTAKE
AIR SOLENOID
VALVE
VARIABLE TUMBLE
SOLENOID VALVE CATCH TANK
PCV VALVE
VARIABLE TUMBLE
OIL SHUTTER VALVE
SEPARATOR ACTUATOR
VENTILATION HOSE
VARIABLE INTAKE AIR
SHUTTER VALVE ACTUATOR
atraaw00001254
End Of Sie
INTAKE MANIFOLD VACUUM INSPECTION[L3]
id0113a2801500
1. Verify that the intake air hoses are installed securely.
3. Disconnect the vacuum hose (purge solenoid valve side) connecting the intake manifold and the purge
solenoid valve and install the vacuum gauge.
4. Measure the intake manifold vacuum while idling using the vacuum gauge.
• If it is not within the specification, perform the following inspection.
— Compression pressure (See 01-10A-9 COMPRESSION INSPECTION[L3].)
— Air suction (installation areas of throttle body, fuel injector, PCV valve, intake manifold)
Standard
–70.0 kPa {–526 mmHg, –21 inHg} or more
End Of Sie
01-13A–4
INTAKE-AIR SYSTEM REMOVAL/INSTALLATION[L3]
id0113a2801900
Warning
• A hot engine and intake air system can cause severe burns. Turn off the engine and wait until they
are cool before removing the intake air system.
• Fuel line spills and leakage from the pressurized fuel system are dangerous. Fuel can ignite and
cause serious injury or death and damage. Fuel can also irritate skin and eyes. To prevent this,
always complete the “Fuel Line Safety Procedure”, while referring to the “BEFORE SERVICE
PRECAUTION”. (See 01-14A-3 BEFORE SERVICE PRECAUTION[L3].) 01
3. Install in the reverse order of removal. .
13
5—8
{51—81,
45—70}
2.5—3.4 8
{26—34, 23—30}
20—26 N·m 1 7.9—11.7 {81—119,
7
{2.1—2.6 kgf·m, 70—103}
15—19 ft·lbf} 8.0—11.5
15 {82—110,
71—100} 9
R 14
12 11 10
16 4 2
2.5—3.4
{26—34, 23—30}
3 A
A
R
16—20 N·m
5
{1.7—2.0 kgf·m,
12—14 ft·lbf}
7.9—11.7 {81—119,
70—103}

atraaw00000570
1 Air cleaner cover 8 Vacuum hose (Purge solenoid valve area)

2 Air cleaner case (See 01-13A-6 Vacuum Hose (Purge Solenoid
Valve Area) Installation Note.)
3 Air cleaner element
9 Air hose
4 Vacuum hose (Catch tank area)
(See 01-13A-6 Vacuum Hose (Purge Solenoid Valve 10 Throttle body
Area) Installation Note.) (See 01-13A-6 Throttle Body Removal Note.)
5 Fresh-air duct 11 Variable tumble solenoid valve
(See 01-13A-6 Fresh-Air Duct Removal Note.) 12 Variable intake air solenoid valve
6 Resonance chamber 13 Wiring harness
(See 01-13A-6 Resonance Chamber Removal 14 Quick release connector
Note.) (See 01-14A-15 QUICK RELEASE CONNECTOR
7 MAF/IAT sensor REMOVAL/INSTALLATION[L3].)
01-13A–5
15 Fuel distributor 16 Intake manifold
(See 01-13A-6 Intake Manifold Removal Note.)
Fresh-Air Duct Removal Note

1. Before removing the fresh-air duct, remove the battery and battery tray. (See 01-17A-2 BATTERY REMOVAL/
INSTALLATION[L3].)
Resonance Chamber Removal Note

1. Before removing the resonance chamber, remove the front tire (LH) and the front side mud guard.
Throttle Body Removal Note

Intake Manifold Removal Note

1. Remove the fan component using the following procedure.
(1) Remove the splash shield.
(2) Remove the front bumper. (See 09-10-1 FRONT BUMPER REMOVAL/INSTALLATION.)
(3) Remove the cooling fan component. (See 01-12A-12 FAN MOTOR REMOVAL/INSTALLATION[L3].)
2. Remove the intake manifold.
Vacuum Hose (Catch Tank Area) Installation Note

1. Install the vacuum hose and clamps as shown in the figure.
AIR CLEANER
PURGE SOLENOID VALVE SIDE CHARCOAL CANISTER SIDE
2—5 mm 0—2 mm
{0.08—0.20 in} {0—0.07 in}
PURGE SOLENOID CLAMP CLAMP

VALVE SIDE
1 mm {0.04 in} 1 mm {0.04 in}
OR LESS OR LESS
CATCH CHARCOAL
TANK CANISTER SIDE
atraaw00000571
Vacuum Hose (Purge Solenoid Valve Area) Installation Note

1. Install the vacuum hose and clamps as shown in
the figure. 2—5 mm {0.08—0.20 in}
End Of Sie
WM: AIR CLEANER
CLAMP
1 mm {0.04 in} MAX
20 mm {0.79 in} MIN
atraaw00000572
AIR CLEANER ELEMENT INSPECTION[L3]

id0113a2800800
1. Remove the air cleaner element. (See 01-13A-5 INTAKE-AIR SYSTEM REMOVAL/INSTALLATION[L3].)
2. Inspect the following items:
• If there is any malfunction, clean or replace the air cleaner element.
• If the replacement date has passed, replace the air cleaner element.
— Is the air cleaner element is soiled, damaged, or bent?
— Are the air cleaner case and the air cleaner element correctly sealed?
— Is the correct air cleaner element installed?
Air cleaner element replacement period

Normal: every 50,000 km {31,069 mile}
Severe condition: every 25,000 km {15,534 mile}
01-13A–6
End Of Sie
THROTTLE BODY INSPECTION[L3]

WM: THROTTLE BODY
id0113a2802600
Note
• Perform the following inspection only when directed.
Resistance Inspection
2. Disconnect the throttle body connector.
3. Measure the resistance between throttle actuator terminals E and F. 01
• If not as specified, replace the throttle body. (See 01-13A-5 INTAKE-AIR SYSTEM REMOVAL/
INSTALLATION[L3].)
• If as specified, carry out the “Circuit Open/Short Inspection”.
Specification
Ambient temperature (°C {°F}) Resistance (ohm)
Approx. 20 {68} 0.3—100
F E D C B A
THROTTLE ACTUATOR
atraaw00000573
Circuit Open/Short Inspection

1. Disconnect the PCM connector. (See 01-40A-7 PCM REMOVAL/INSTALLATION[L3].)
2. Inspect the following wiring harnesses for an
open or short circuit (Continuity check).
THROTTLE ACTUATOR
HARNESS SIDE CONNECTOR
F E D C B A
atraaw00000574
PCM
WIRING HARNESS-SIDE CONNECTOR
2BE 2BA 2AW 2AS 2AO 2AK 2AG 2AC 2Y 2U 2Q 2M 2I 2E 2A 1BE 1BA 1AW 1AS 1AO 1AK 1AG 1AC 1Y 1U 1Q 1M 1I 1E 1A
2BF 2BB 2AX 2AT 2AP 2AL 2AH 2AD 2Z 2V 2R 2N 2J 2F 2B 1BF 1BB 1AX 1AT 1AP 1AL 1AH 1AD 1Z 1V 1R 1N 1J 1F 1B
2BG 2BC 2AY 2AU 2AQ 2AM 2AI 2AE 2AA 2W 2S 2O 2K 2G 2C 1BG 1BC 1AY 1AU 1AQ 1AM 1AI 1AE 1AA 1W 1S 1O 1K 1G 1C
2BH 2BD 2AZ 2AV 2AR 2AN 2AJ 2AF 2AB 2X 2T 2P 2L 2H 2D 1BH 1BD 1AZ 1AV 1AR 1AN 1AJ 1AF 1AB 1X 1T 1P 1L 1H 1D
atraaw00000575
Open circuit
• If there is no continuity, the circuit is open. Repair or replace the wiring harness.
— Throttle actuator terminal F and PCM terminal 2A
— Throttle actuator terminal E and PCM terminal 2B
01-13A–7
Short circuit
• If there is continuity, the circuit is shorted. Repair or replace the wiring harness.
— Throttle actuator terminal E and power supply
— Throttle actuator terminal E and ground
— Throttle actuator terminal F and power supply
— Throttle actuator terminal F and ground
End Of Sie
VARIABLE INTAKE AIR SOLENOID VALVE INSPECTION[L3]
WM: VARIABLE INTAKE-AIR SOLENOID VALVE
id0113a2802800
1. Remove the variable intake air solenoid valve. (See 01-13A-5 INTAKE-AIR SYSTEM REMOVAL/
INSTALLATION[L3].)
2. Inspect airflow between the ports under the following conditions.
• If not as specified, replace the variable intake air solenoid valve. (See 01-13A-5 INTAKE-AIR SYSTEM
: Continuity : Airflow
Terminal Port
Step B
A B A B C
B A
1 C A
2 B+ GND
atraaw00000576
atraaw00000577

2. Inspect the following wiring harness for an open
or short circuit (Continuity check). VARIABLE INTAKE AIR FUSE BOX
SOLENOID VALVE (MAIN RELAY)
B
A E
B A FRONT
D
atraaw00000578
PCM
atraaw00000579
Open circuit
— Variable intake air solenoid valve terminal A and main relay terminal A
— Variable intake air solenoid valve terminal B and PCM terminal 2AJ
01-13A–8
Short circuit
— Variable intake air solenoid valve terminal A and body ground
— Variable intake air solenoid valve terminal B and power supply
— Variable intake air solenoid valve terminal B and body ground
End Of Sie
VARIABLE TUMBLE SOLENOID VALVE INSPECTION[L3]
WM: VARIABLE TUMBLE SOLENOID VALVE
id0113a2802900
1. Remove the variable tumble solenoid valve. (See 01-13A-5 INTAKE-AIR SYSTEM REMOVAL/
INSTALLATION[L3].) 01
• If not as specified, replace the variable tumble solenoid valve. (See 01-13A-5 INTAKE-AIR SYSTEM
Terminal Port
Step
A B A B C
B A B
1
2 B+ GND C A
atraaw00000580
atraaw00000581

VARIABLE TUMBLE FUSE BOX
or short circuit (Continuity check).
SORENOID VALVE (MAIN RELAY)
B
A E
B A FRONT
D
atraaw00000582
PCM
atraaw00000583
Open circuit
— Variable tumble solenoid valve terminal A and main relay terminal A
— Variable tumble solenoid valve terminal B and PCM terminal 2AI
01-13A–9
Short circuit
— Variable tumble solenoid valve terminal A and body ground
— Variable tumble solenoid valve terminal B and power supply
— Variable tumble solenoid valve terminal B and body ground
End Of Sie
VARIABLE INTAKE AIR SHUTTER VALVE ACTUATOR INSPECTION[L3]
WM: VARIABLE INTAKE-AIR SHUTTER VALVE ACTUATOR
id0113a2803000
1. Remove the air hose. (See 01-13A-5 INTAKE-AIR SYSTEM REMOVAL/INSTALLATION[L3].)
2. Disconnect the vacuum hose from the variable VARIABLE INTAKE AIR
intake air shutter valve actuator. SOLENOID VALVE
3. Connect a vacuum pump to the variable intake air
shutter valve actuator.
4. Apply vacuum and verify that the rod moves.
• If the rod dose not move, replace the intake
manifold.
Vacuum
Rod movement
kPa {mmHg, inHg}
Below –2.7 {–20, –0.7} Starts to move
VARIABL INTAKE AIR
Above –33.4 {–251, –9.9} Fully pulled SHUTTER VALVE ACTUATOR
atraaw00000585
End Of Sie
VARIABLE TUMBLE SHUTTER VALVE ACTUATOR INSPECTION[L3]
WM: VARIABLE TUMBLE SHUTTER VALVE ACTUATOR
id0113a2803100
2. Disconnect the vacuum hose from the variable
tumble shutter valve actuator.
3. Connect a vacuum pump to the variable tumble VARIABLE TUMBLE
shutter valve actuator. SOLENOID VALVE
4. Apply vacuum and verify that the rod moves.
• If the rod dose not move, replace the intake
manifold.
Vacuum
Rod movement
kPa {mmHg, inHg}
Below –2.7 {–20, –0.7} Starts to move
Above –33.4 {–251, –9.9} Fully pulled
End Of Sie
WM: ACCELERATOR PEDAL
VARIABLE TUMBLE
SHUTTER VALVE
ACTUATOR
atraaw00000586
ACCELERATOR PEDAL REMOVAL/INSTALLATION[L3]

id0113a2801400
1 Connector 1
2 Accelerator pedal
3 Bracket 7.8—10.8 {80—110,
69—95}
End Of Sie
3
2 7.8—10.8 {80—110,
69—95}
{kgf·cm, in·lbf}
atraaw00001125
01-13A–10
INTAKE-AIR SYSTEM [AJ (3.0L Duratec)]
01-13B INTAKE-AIR SYSTEM [AJ (3.0L Duratec)]

INTAKE-AIR SYSTEM HOSE ROUTING FRESH-AIR DUCT
DIAGRAM[AJ (3.0L Duratec)] . . . . . . . 01-13B–1 REMOVAL/INSTALLATION
INTAKE-AIR SYSTEM LOCATION [AJ (3.0L Duratec)] . . . . . . . . . . . . . . . . 01-13B–8
INDEX[AJ (3.0L Duratec)] . . . . . . . . . . 01-13B–2 AIR HOSE REMOVAL/INSTALLATION
INTAKE-AIR SYSTEM DIAGRAM [AJ (3.0L Duratec)] . . . . . . . . . . . . . . . . 01-13B–9
[AJ (3.0L Duratec)] . . . . . . . . . . . . . . . . 01-13B–3 THROTTLE BODY
INTAKE-AIR SYSTEM MANIFOLD REMOVAL/INSTALLATION 01
VACUUM INSPECTION [AJ (3.0L Duratec)] . . . . . . . . . . . . . . . . 01-13B–9
[AJ (3.0L Duratec)] . . . . . . . . . . . . . . . . 01-13B–3 IDLE AIR CONTROL (IAC) SOLENOID
AIR CLEANER VALVE REMOVAL/INSTALLATION
[AJ (3.0L Duratec)] . . . . . . . . . . . . . . . . 01-13B–4 IDLE AIR CONTROL (IAC) SOLENOID
INTAKE MANIFOLD VALVE INSPECTION
[AJ (3.0L Duratec)] . . . . . . . . . . . . . . . . 01-13B–4 ACCELERATOR CABLE BRACKET
DYNAMIC CHAMBER REMOVAL/INSTALLATION
[AJ (3.0L Duratec)] . . . . . . . . . . . . . . . . 01-13B–6 ACCELERATOR PEDAL
RESONANCE CHAMBER REMOVAL/INSTALLATION
[AJ (3.0L Duratec)] . . . . . . . . . . . . . . . . 01-13B–8
End of Toc
INTAKE-AIR SYSTEM HOSE ROUTING DIAGRAM[AJ (3.0L Duratec)]
NG: INTAKE-AIR SYSTEM
id0113a1100400
EGR CONTROL VALVE
EGR VALVE
TO CHARCOAL CANISTER
PCV VALVE
VENTILATION HOSE
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End Of Sie
WM: INTAKE-AIR SYSTEM
01-13B–1
INTAKE-AIR SYSTEM LOCATION INDEX[AJ (3.0L Duratec)]
id0113a1801700
3
8
2 7
4
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Air cleaner Throttle body

1 (See 01-13B-4 AIR CLEANER REMOVAL/ 6 (See 01-13B-9 THROTTLE BODY REMOVAL/
Intake manifold Idle air control (IAC) valve
2 (See 01-13B-4 INTAKE MANIFOLD REMOVAL/ (See 01-13B-10 IDLE AIR CONTROL (IAC)
INSTALLATION[AJ (3.0L Duratec)].) SOLENOID VALVE REMOVAL/INSTALLATION[AJ
Dynamic chamber 7 (3.0L Duratec)].)
3 (See 01-13B-6 DYNAMIC CHAMBER REMOVAL/ (See 01-13B-10 IDLE AIR CONTROL (IAC)
INSTALLATION[AJ (3.0L Duratec)].) SOLENOID VALVE INSPECTION[AJ (3.0L
Duratec)].)
Resonance chamber
4 (See 01-13B-8 RESONANCE CHAMBER Accelerator cable
REMOVAL/INSTALLATION[AJ (3.0L Duratec)].) (See 01-13B-11 ACCELERATOR CABLE
8
BRACKET REMOVAL/INSTALLATION[AJ (3.0L
Fresh-air duct Duratec)].)
5 (See 01-13B-8 FRESH-AIR DUCT REMOVAL/
INSTALLATION[AJ (3.0L Duratec)].) Accelerator pedal
9 (See 01-13B-12 ACCELERATOR PEDAL
End Of Sie
01-13B–2
INTAKE-AIR SYSTEM DIAGRAM[AJ (3.0L Duratec)]
id0113a1801600
DYNAMIC CHAMBER THROTTLE BODY FRESH-AIR DUCT
01
IAC SOLENOID VALVE AIR CLEANER
RESONANCE
INTAKE MANIFOLD CHAMBER
:INTAKE AIR FLOW

:TO PCM
aesffw00000455
End Of Sie
INTAKE-AIR SYSTEM MANIFOLD VACUUM INSPECTION[AJ (3.0L Duratec)]
id0113a1801800
1. Verify that the intake air hoses are installed securely.
2. Disconnect the vacuum hose connecting the intake manifold and the purge solenoid valve (purge solenoid
valve side) and install the vacuum gauge.
4. Measure the intake manifold vacuum while idling (no load) using the vacuum gauge.
• If not within the specification, perform the following inspections.
— Compression pressure
— Air intake
• Each hose installation part
• Throttle body installation part
• Fuel injector installation part
• PCV valve installation part
• Dynamic chamber installation port
• Intake manifold installation part
Standard intake manifold vacuum

• Approx. –67.4 kPa {–505 mmHg, –19.9 inHg}
End Of Sie
WM: AIR CLEANER
01-13B–3
AIR CLEANER REMOVAL/INSTALLATION[AJ (3.0L Duratec)]
id0113a1802500
2. Disconnect the air hose. (See 01-13B-9 AIR MAF/IAT
HOSE REMOVAL/INSTALLATION[AJ (3.0L SENSOR
Duratec)].) AIR HOSE
3. Disconnect the mass air flow (MAF)/intake air
temperature (IAT) sensor connector.
AIR CLEANER
atraaw00000081
4. Remove the air cleaner.
Note
• Verify that the two air cleaner supports are
securely installed to the rubber grommet
under the air cleaner.
• To prevent unmeasured air from entering the
engine, securely seal the air hose.
5. Install in the reverse order of removal. AIR CLEANER
Air cleaner installation bolt tightening torque

atraaw00000082
7.9—11.7 N·m {81—119 kgf·cm, 70—103
in·lbf}
Air hose clamp tightening torque
2.5—3.4 N·m {26—34 kgf·cm, 23—30 in·lbf}
End Of Sie
INTAKE MANIFOLD REMOVAL/INSTALLATION[AJ (3.0L Duratec)]
WM: INTAKE MANIFOLD
id0113a1802000
Warning
• Fuel is hazardous. It can very easily ignite, causing serious injury and damage. Always keep
skin and eyes. To prevent this, always perform the 'Fuel Line Safety Procedure'.
• A person charged with static electricity could cause a fire or explosion, resulting in death or
serious injury. Before performing work on the fuel system, discharge static electricity by touching
the vehicle body.
Caution
• Foreign objects in the joint of the quick release connector may possibly cause damage to the fuel
pipe and quick release connector. To prevent this, always clean the quick release connector joint
area before disconnecting/connecting.

2. Complete the “BEFORE SERVICE PRECAUTION”. (See 01-14B-4 BEFORE SERVICE PRECAUTION[AJ
(3.0L Duratec)].)
3. Disconnect the quick release connector. (See 01-14B-11 QUICK RELEASE CONNECTOR REMOVAL/
Duratec)].)
01-13B–4
5. Disconnect the fuel injector connector.
6. Disconnect the vacuum hose. VACUUM HOSE
01
FUEL INJECTOR
CONNECTOR
atraaw00001016
7. Remove the intake manifold installation bolts.

8. Remove the intake manifold and fuel distributor as
a unit.
INTAKE MANIFOLD
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9. Remove the fuel distributor installation bolts at

four points. FUEL DISTRIBUTOR
10. Remove the intake manifold from the fuel
distributor.
11. Remove the six fuel injectors from the intake
manifold.
Note
• If there is damage to the gasket, replace with
a new gasket.

atraaw00001018
Intake manifold installation bolt tightening

torque
8—12 N·m {82—122 kgf·cm, 71—106 lbf·in}
13. Complete the “AFTER SERVICE PRECAUTION”. (See 01-14B-4 AFTER SERVICE PRECAUTION[AJ (3.0L
Duratec)].)
End Of Sie
WM: DYNAMIC CHAMBER
01-13B–5
DYNAMIC CHAMBER REMOVAL/INSTALLATION[AJ (3.0L Duratec)]
id0113a1802100
3. Remove the air hose. (See 01-13B-9 AIR HOSE
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4. Detach the throttle cable from the throttle body. SPEED CONTROL CABLE
5. Detach the speed control cable from the throttle
body. (Only vehicles with speed control cable) ACCELERATOR
6. Remove the throttle cable bracket bolts. CABLE
THROTTLE CABLE
BRACKET BOLT
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7. Disconnect the throttle position (TP) sensor and IAC SOLENOID VALVE
idle air control (IAC) solenoid valve connector.
TP SENSOR
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8. Remove the EGR valve vacuum hose and EGR

pipe nut. VACUUM HOSE
EGR VALVE
EGR PIPE
atraaw00001001
01-13B–6
9. Disconnect the following hoses or connectors.
(1) EGR control valve connector and vacuum
hose EGR CONTROL VALVE
(2) Three vacuum hoses located behind the
dynamic chamber
VACUUM HOSE
01
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(3) Purge solenoid valve vacuum hose
atraaw00000092
(4) Two connectors installed on the left side of the

dynamic chamber
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(5) Power steering pressure (PSP) switch

connector
PSP SWITCH
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01-13B–7
10. Remove the dynamic chamber installation bolts
and dynamic chamber.
Note
• If the gasket is damaged, replace with a new
one.
• Clean all of the sealing surfaces.
Plug hole plate installation nut tightening

torque
atraaw00000095
5.2—7.2 N·m {53—73 kgf·cm, 46—63 lbf·in}
Dynamic chamber installation bolt tightening
torque
8—12 N·m {82—122 kgf·cm, 71—106 lbf·in}
End Of Sie
RESONANCE CHAMBER REMOVAL/INSTALLATION[AJ (3.0L Duratec)]
WM: RESONANCE CHAMBER
id0113a1802200
1. Remove the seven pin-type retainers and four
screws, and then position the inner fender splash
shield (LH) out of the way.
INNER FENDER SPLASH

SHIELD (LH)
atraaw00000078
2. Remove the resonance chamber installation bolt

and resonance chamber.
Note
• Verify that the front rubber grommet is
installed securely to the bracket.
Resonance chamber installation bolt

RESONANCE CHAMBER
tightening torque
Approx. 8 N·m {82 kgf·cm, 71 in·lbf}
atraaw00000079
End Of Sie
FRESH-AIR DUCT REMOVAL/INSTALLATION[AJ (3.0L Duratec)]
WM: FRESH-AIR DUCT
id0113a1802300
1. Remove the air cleaner. (See 01-13B-4 AIR CLEANER REMOVAL/INSTALLATION[AJ (3.0L Duratec)].)
2. Remove the battery.
3. Remove the battery tray.
4. Remove the fresh-air duct installation bolt and
fresh-air duct.
Note
• Verify that the front sponge seal for the
fresh-air duct is installed correctly to the
shroud panel.

FRESH-AIR
Fresh-air duct installation bolt tightening DUCT
torque
atraaw00000083
7.9—11.7 N·m {81—119 kgf·cm, 70—103
in·lbf}
01-13B–8
End Of Sie
AIR HOSE REMOVAL/INSTALLATION[AJ (3.0L Duratec)]

WM: AIR HOSE
id0113a1802400
1. Disconnect the crankcase vent hose. CRANKCASE
2. Loosen the air hose clamp and remove the air VENT HOSE
hose.
Air hose clamp tightening torque

2.5—3.4 N·m {26—34 kgf·cm, 23—30 in·lbf}
01
End Of Sie
WM: THROTTLE BODY
AIR HOSE
atraaw00000080
THROTTLE BODY REMOVAL/INSTALLATION[AJ (3.0L Duratec)]

id0113a1802700
Warning
• Fuel vapor is hazardous. It can easily ignite, causing serious injury and damage. To prevent this,
always keep sparks and flames away when handling fuel system components and keep them away
from the components near the fuel system.
Caution
• Since the throttle body bore and plate area have a special coating, they cannot be cleaned.

3. Remove the air hose. (See 01-13B-9 AIR HOSE
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4. Detach the accelerator cable and speed control

cable. (Only vehicles with cruise control system)
ACCELERATOR CABLE
SPEED CONTROL
CABLE
atraaw00000097
5. Disconnect the throttle position (TP) sensor

connector. TP SENSOR
atraaw00000098
01-13B–9
6. Remove the throttle body.
Note
• Replace the gasket with a new one.
Throttle body installation bolt tightening

torque
Plug hole plate installation nut tightening THROTTLE BODY
torque
atraaw00000099
5—7 N·m {51—71 kgf·cm, 45—61 lbf·in}
End Of Sie
IDLE AIR CONTROL (IAC) SOLENOID VALVE REMOVAL/INSTALLATION[AJ (3.0L Duratec)]
WM: IAC SOLENOID VALVE
id0113a1805100
2. Disconnect the IAC solenoid valve connector.
3. Remove the IAC solenoid valve installation bolts
and IAC solenoid valve.
Note

IAC SOLENOID VALVE
IAC solenoid valve installation bolt tightening
torque
atraaw00000084
End Of Sie
IDLE AIR CONTROL (IAC) SOLENOID VALVE INSPECTION[AJ (3.0L Duratec)]
id0113a1803300
2. Disconnect the IAC solenoid valve connector.
3. Using a tester, measure the resistance between the IAC solenoid valve terminals.
• If it is within the specification, inspect the related harnesses.
• If it is not within the specification, replace the IAC solenoid valve.
IAC solenoid valve resistance

8.8—10.6 ohms [24 °C {75 °F}]
atraaw00000085
01-13B–10
1. Disconnect the PCM connector. (See 01-40B-6 PCM REMOVAL/INSTALLATION[AJ (3.0L Duratec)].)
2. Inspect the following wiring harness for open or short (continuity check).
IAC SOLENOID VALVE
MAIN FUSE BLOCK
(FUEL PUMP RELAY)
B
B A A E 01
FRONT D
PCM
26 25 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
52 51 50 49 48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27
78 77 76 75 74 73 72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53
104103102 101100 99 98 97 96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79
atraaw00003255
Open circuit
• If there is no continuity, the circuit is open. Repair or replace the harness.
— IAC solenoid valve terminal A and main relay terminal B
— IAC solenoid valve terminal B and PCM terminal 83
Short circuit
• If there is continuity, the circuit is shorted. Repair or replace the harness.
— IAC solenoid valve terminal A and body ground
— IAC solenoid valve terminal B and power supply
End Of Sie
ACCELERATOR CABLE BRACKET REMOVAL/INSTALLATION[AJ (3.0L Duratec)]
WM: ACCELERATOR CABLE
id0113a1803400
atraaw00000107
01-13B–11
2. For vehicles with a speed control cable, detach
the speed control cable from the throttle lever. ACCELERATOR CABLE
3. Rotate the throttle lever and remove the
accelerator cable end from the throttle lever. THROTTLE LEVER
ACCELERATOR CABLE END
atraaw00000130
4. Detach the accelerator cable from the bracket.

5. For vehicles with a speed control cable, push in ACCELERATOR CABLE
the tabs and detach the speed control cable from
the accelerator cable bracket.
SPEED CONTROL CABLE
atraaw00000108
6. Remove the accelerator cable bracket.

Accelerator cable bracket installation bolt

tightening torque
torque
5—7 N·m {51—71 kgf·cm, 45—61 lbf·in}
End Of Sie
WM: ACCELERATOR PEDAL
atraaw00000109
ACCELERATOR PEDAL REMOVAL/INSTALLATION[AJ (3.0L Duratec)]

id0113a1801400
atraaw00000107
01-13B–12
2. Rotate the throttle lever and remove the
accelerator cable end from the throttle lever. ACCELERATOR CABLE
THROTTLE LEVER
ACCELERATOR CABLE END
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3. Detach the accelerator cable from the panel.

4. Remove the installation bolts of the accelerator
pedal and shaft, and then remove the accelerator
pedal and shaft.
5. To ensure installation serviceability, remove the
grommet from the throttle lever and install it to the ACCELERATOR
CABLE
accelerator cable end.
Accelerator pedal, shaft installation bolt

tightening torque
atraaw00000102
torque
5—7 N·m {51—71 kgf·cm, 45—61 lbf·in}
End Of Sie
01-13B–13
FUEL SYSTEM [L3]
01-14A FUEL SYSTEM [L3]

FUEL SYSTEM FLOW DIAGRAM FUEL PUMP UNIT
[L3] . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-14A–1 DISASSEMBLY/ASSEMBLY[L3] . . . . . . 01-14A–13
FUEL SYSTEM LOCATION INDEX FUEL PUMP UNIT INSPECTION[L3]. . . . 01-14A–13
[L3] . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-14A–2 FUEL FILTER (HIGH-PRESSURE)
BEFORE SERVICE PRECAUTION REMOVAL/INSTALLATION[L3] . . . . . . . 01-14A–14
[L3] . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-14A–3 QUICK RELEASE CONNECTOR
AFTER SERVICE PRECAUTION REMOVAL/INSTALLATION[L3] . . . . . . . 01-14A–15 01
[L3] . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-14A–4 FUEL INJECTOR
FUEL LINE PRESSURE INSPECTION REMOVAL/INSTALLATION[L3] . . . . . . . 01-14A–18
[L3] . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-14A–5 FUEL INJECTOR INSPECTION[L3] . . . . 01-14A–19
FUEL TANK REMOVAL/INSTALLATION FUEL PUMP STOP SWITCH
[L3] . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-14A–6 REMOVAL/INSTALLATION[L3] . . . . . . . 01-14A–23
FUEL TANK INSPECTION[L3] . . . . . . . . 01-14A–9 FUEL PUMP STOP SWITCH
NONRETURN VALVE INSPECTION INSPECTION[L3] . . . . . . . . . . . . . . . . . . 01-14A–24
[L3] . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-14A–10
FUEL PUMP UNIT
REMOVAL/INSTALLATION[L3] . . . . . . 01-14A–10
End of Toc
FUEL SYSTEM FLOW DIAGRAM[L3]
NG: FUEL SYSTEM
id0114a2100300
FUEL FILTER (HIGH-PRESSURE SIDE)
FUEL TANK
FUEL INJECTOR
PRESSURE
REGULATOR FUEL FILTER
(LOW-PRESSURE SIDE)
FUEL PUMP
: FUEL FLOW
atraaw00001148
End Of Sie
WM: FUEL SYSTEM
01-14A–1
FUEL SYSTEM [L3]
FUEL SYSTEM LOCATION INDEX[L3]
id0114a2800100
Engine compartment side
atraaw00000824
1 Fuel injector 3 Fuel pump stop switch

(See 01-14A-18 FUEL INJECTOR REMOVAL/ (See 01-14A-23 FUEL PUMP STOP SWITCH
INSTALLATION[L3].) REMOVAL/INSTALLATION[L3].)
(See 01-14A-19 FUEL INJECTOR (See 01-14A-24 FUEL PUMP STOP SWITCH
INSPECTION[L3].) INSPECTION[L3].)
2 Fuel pump relay 4 Quick release connector
(See 01-14A-15 QUICK RELEASE CONNECTOR
01-14A–2
FUEL SYSTEM [L3]
Fuel tank side
5
1
01
3
2
5
atraaw00000825
1 Fuel tank 3 Fuel filter (high-pressure)

(See 01-14A-6 FUEL TANK REMOVAL/ (See 01-14A-14 FUEL FILTER (HIGH-PRESSURE)
INSTALLATION[L3].) REMOVAL/INSTALLATION[L3].)
(See 01-14A-9 FUEL TANK INSPECTION[L3].) 4 Nonreturn valve
2 Fuel pump unit (See 01-14A-10 NONRETURN VALVE
(See 01-14A-10 FUEL PUMP UNIT REMOVAL/ INSPECTION[L3].)
INSTALLATION[L3].) 5 Quick release connector
(See 01-14A-13 FUEL PUMP UNIT DISASSEMBLY/ (See 01-14A-15 QUICK RELEASE CONNECTOR
ASSEMBLY[L3].) REMOVAL/INSTALLATION[L3].)
(See 01-14A-13 FUEL PUMP UNIT
INSPECTION[L3].)
End Of Sie
BEFORE SERVICE PRECAUTION[L3]
id0114a2802000
Warning
cause death or serious injuries and damage. Fuel can also irritate skin and eyes. To prevent this,
always perform the "Fuel Line Safety Procedure".
the vehicle body.
Caution
01-14A–3
FUEL SYSTEM [L3]
Fuel Line Safety Procedure
1. Remove the fuel-filler cap to release the pressure inside the fuel tank.
2. Remove the fuel pump relay.
3. Start the engine. FUEL PUMP RELAY
4. After engine stalling, crank the engine several
times.
5. Turn the ignition switch to the LOCK position.
End Of Sie
atraaw00000826
AFTER SERVICE PRECAUTION[L3]

id0114a2801900
Warning
• Fuel is hazardous. It can very easily ignite, causing death or serious injury and damage. Fuel can
also irritate skin and eyes. To prevent this, always perform the "Fuel Line Safety Procedure".
Fuel Leakage Inspection
Warning
also irritate skin and eyes. To prevent this, always carry out the following procedure with the
engine stopped.
Caution
• Fuel pump operation without fuel in the fuel tank may possible cause malfunction. Verify that there
is sufficient fuel in the tank for pump suction.
1. Start the fuel pump using the following procedure.

Using PDS/IDS
1. Connect the PDS/IDS to the DLC-2.
2. Using the simulation function “FP”, start the
fuel pump.
Without using PDS/IDS
Caution
• Short the specified terminals because
shorting the wrong terminal of the main
fuse block may cause malfunctions.
DLC-2
aesffw00000044
3. Using a jumper wire, short fuel pump relay

terminals A and E in the main fuse block. MAIN FUSE BLOCK
4. Connect the negative battery cable and (FUEL PUMP RELAY)
operate the fuel pump.
B
2. Verify that there is no fuel leakage where work is
being performed while the fuel is pressurized. A E
• If there is leakage, replace the fuel hoses and FRONT
D
clips.
• If there is damage on the seal on the fuel pipe
side, replace the fuel pipe.
Standard
atraaw00000831
No leakage after 5 min.
3. After reinstallation, repeat step 1 to 3 in the fuel leakage inspection.

End Of Sie
01-14A–4
FUEL SYSTEM [L3]
FUEL LINE PRESSURE INSPECTION[L3]
id0114a2800500
Warning
cause death or serious injuries and damage. To prevent this, always carry out the following
procedure with the engine stopped.
1. Perform the "Fuel Line Safety Procedure" referring to the BEFORE SERVICE PRECAUTION. (See 01-14A-3
BEFORE SERVICE PRECAUTION[L3].) 01
3. Disconnect the quick release connector of the engine compartment side. (See 01-14A-15 QUICK RELEASE
CONNECTOR REMOVAL/INSTALLATION[L3].)
4. Turn the lever of the SST parallel to the hose as
LEVER 49 N013 1A0D
shown in the figure.
5. Insert the SST quick release connector into the
fuel pipe until a click is heard.
6. Verify that the installation is secure by pulling the
quick release connector.
FROM THE
Using PDS/IDS
FUEL TANK
atraaw00000835

fuel pump.
Caution
DLC-2
aesffw00000045

(FUEL PUMP RELAY)
3. Connect the negative battery cable and
8. Operate the fuel pump for 10 s. B
9. Measure the fuel line pressure. A E
• If not within the specification, inspect the FRONT
following: D
If it less than the specification:
— Fuel pump unit
— Fuel leakage
If it exceeds the specification:
atraaw00001149
— Pressure regulator clogging
Fuel line pressure (Reference)

380—420 kPa {3.88—4.28 kgf/cm2, 55.2—60.9 psi}
01-14A–5
FUEL SYSTEM [L3]
10. Stop the fuel pump using the following procedure:
Using PDS/IDS
1. Stop the fuel pump using the FP simulation function.
1. Disconnect the negative battery cable to stop the fuel pump.
11. Measure the fuel hold pressure after 5 min.
• If not within the specification, inspect the following:
— Fuel line for clogging or leakage
Fuel hold pressure (Reference)

176 kPa {1.79 kgf/cm2, 25.5 psi} or more
12. Disconnect the SST.

13. Connect the quick release connector. (See 01-14A-15 QUICK RELEASE CONNECTOR REMOVAL/
INSTALLATION[L3].)
14. Inspect all parts by performing the AFTER SERVICE PRECAUTION. (See 01-14A-4 AFTER SERVICE
PRECAUTION[L3].)
End Of Sie
FUEL TANK REMOVAL/INSTALLATION[L3]
WM: FUEL TANK
id0114a2801600
Warning
• Repairing a fuel tank that has not been properly steam cleaned is dangerous. Explosion or fire
may cause death or serious injury. Always properly steam clean a fuel tank before repairing it.
serious injury. Before draining fuel, make sure to discharge static electricity by touching the
vehicle body.
1. Park the vehicle on a level surface.

BEFORE SERVICE PRECAUTION[L3].)
4. Remove the fuel pump unit. (See 01-14A-10 FUEL PUMP UNIT REMOVAL/INSTALLATION[L3].)
5. Drain the fuel from the service hole.
6. Remove the rear tire (LH) (See 02-12-7 WHEEL AND TIRE REMOVAL/INSTALLATION.)
7. Remove the main silencer. (See 01-15A-2 EXHAUST SYSTEM REMOVAL/INSTALLATION[L3].)
8. Remove in the order indicated in the figure.
01-14A–6
FUEL SYSTEM [L3]
10. Inspect all parts by performing the AFTER SERVICE PRECAUTION. (See 01-14A-4 AFTER SERVICE
PRECAUTION[L3].)
5 2.5—3.5
01
{25—36, 22—31}
B
8.82—12.74
3 {89.9—129,
6 78.1—112} 4
A
1
43—61 N·m {4.4—6.2 kgf·m,

32—44 ft·lbf}
atraaw00000838
1 Joint hose 4 Protector

(See 01-14A-9 Joint Hose Installation Note.) (See 01-14A-8 Protector Removal Note.)
2 Breather hose 5 Fuel-filler pipe
(See 01-14A-8 Breather Hose Installation Note.) 6 Nonreturn valve
3 Fuel tank
(See 01-14A-7 Fuel Tank Removal Note.)
Fuel Tank Removal Note

1. Remove the propeller shaft. (See 03-15-4 PROPELLER SHAFT REMOVAL/INSTALLATION.)
2. Position the rear differential out of way.
3. Remove the fuel tank.
01-14A–7
FUEL SYSTEM [L3]
Protector Removal Note
Caution
• Be careful not to damage the fuel tank when removing the rivet. If the fuel tank is damaged, it may
cause fuel leakage.
Note
• The insulator is installed using rivets.
• When resin stalling the rivet, install the same rivet or M5 bolt and nut.
1. Push out the mandrel using a hammer and punch HAMMER

(2—2.8 mm {0.08—0.11 in} diameter).
2. Remove the flange using a drill (5 mm {0.20 in}
drill bit). INSULATOR
FUEL TANK MANDREL
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DRILL
FLANGE
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Breather Hose Installation Note

1. Install the breather hose and clamps as shown in
the figure.
10mm {0.39 in}
CLAMP
BREATHER HOSE
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01-14A–8
FUEL SYSTEM [L3]
Joint Hose Installation Note
1. Install the joint hose and clamps as shown in the
figure. VIEW A
15 {0.59}
JOINT HOSE
8—12
{0.32— FUEL TANK
0.47} SIDE
3 {0.12}
01
CLAMP
OR LESS
mm {in}
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End Of Sie
VIEW B
20 {0.79}
JOINT HOSE
FUEL
FILLER
PIPE SIDE
8—12
{0.32—
0.47} 5 {0.19} CLAMP
OR LESS
mm {in}
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FUEL TANK INSPECTION[L3]

id0114a2803200
Note
• This inspection is for two rollover valves integrated in the fuel tank.
3. Remove the fuel tank. (See 01-14A-6 FUEL TANK REMOVAL/INSTALLATION[L3].)
4. Remove the residual fuel.
5. Install the fuel pump unit. (See 01-14A-10 FUEL PUMP UNIT REMOVAL/INSTALLATION[L3].)
6. Plug the fuel pipe, breather pipe and port C of the
C
fuel pump unit. B
7. Place the fuel tank in a level position.
8. Blow through port B and verify that there is airflow BREATHER PIPE
from port A. FUEL PIPE
• If there is no airflow, replace the fuel tank.
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9. Turn the fuel tank upside-down. Blow through port

B and verify that there is no airflow from port A.
• If there is airflow, replace the fuel tank. (See
01-14A-6 FUEL TANK REMOVAL/
INSTALLATION[L3].) A
End Of Sie
FUEL PIPE
WM: NONRETURN VALVE
BREATHER PIPE
B
C
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01-14A–9
FUEL SYSTEM [L3]
NONRETURN VALVE INSPECTION[L3]
id0114a2803600
1. Remove the fuel-filler pipe. (See 01-14A-6 FUEL TANK REMOVAL/INSTALLATION[L3]..)
2. Verify that the nonreturn valve opens up to 90°
when it is pushed from the fuel-filler pipe side,
NONRETURN VALVE FUEL-FILLER PIPE
and it returns to the normal position by spring
force.
• If the nonreturn valve does not open up to 90°
or does not return to the normal position,
replace the nonreturn valve.
End Of Sie
WM: FUEL PUMP
90°
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FUEL PUMP UNIT REMOVAL/INSTALLATION[L3]

id0114a2800900
Warning
Safety Procedure”.
damage. Fuel can also irritate skin and eyes. To prevent this, before performing the fuel pump unit
removal/installation, always complete the “Fuel Leak Inspection After Fuel Pump Unit
Installation”.
vehicle body.
Caution
• Because the fuel tank is constructed such that the fuel level is higher than the installation surface
of the fuel pump, fuel leakage could occur. If the fuel gauge indicates a fuel level of half or more,
perform the following Steps 1-8 to drain approx. 10 L {11 US gal, 8.8 lmp gal} of fuel.
• Disconnecting/connecting the quick release connector without cleaning it may possibly cause
damage to the fuel pipe and quick release connector. Always clean the quick release connector
joint area before disconnecting/connecting using a cloth or soft brush, and make sure that it is
free of foreign material.
• To prevent the SST from coming off the fuel pump cap while performing the work, always perform
the removal/installation procedure with 2 people. One person presses the SST against cap from
directly above, while the other person rotates the SST.
• If there is foreign material on the connecting area of the quick release connector, it might damage
the connector or fuel pipe. To prevent this, disconnect the connector and clean the connecting
area before connecting.
(3.0L Duratec)].)
2. Lift the rear seat cushion (LH).
3. Remove the scuff plate and turn over the carpet.
4. Remove the service hole cover.
SERVICE HOLE COVER
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01-14A–10
FUEL SYSTEM [L3]
5. Disconnect the quick release connector as shown
QUICK RELEASE
in the figure.
CONNECTOR
FRONT
01
LH REAR DOOR
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6. Connect a hose to the fuel pump unit.

7. Drain the fuel into a container used for collecting
gasoline.
8. Start the fuel pump using the following procedure. HOSE
Using PDS/IDS
FRONT
LH REAR DOOR
aesffw00000049

fuel pump.
Caution
DLC-2
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4. Connect the negative battery cable and (FUEL PUMP RELAY)
operate the fuel pump. B
Caution A E
FRONT
• The fuel pump could be damaged if it is
operated (fuel pump idling) while there is D
no fuel in the fuel tank. Verify the amount
of fuel being discharged from the hose
and stop operation of the fuel pump
when essentially no fuel is being
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discharged.

01-14A–11
FUEL SYSTEM [L3]
12. Inspect all parts by performing AFTER SERVICE
PRECAUTION. (See 01-14A-4 AFTER SERVICE 2 SST
88.2—107.8
PRECAUTION[L3].) {9.0—10.9, 65.1—79.5}
1 Fuel pump unit connector
2 Fuel pump cap
(See 01-14A-12 Fuel pump cap removal note.) 1
(See 01-14A-13 Fuel pump cap installation note.)
3 Fuel pump unit 3

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Fuel pump cap removal note
Caution
• The fuel pump cap could be damaged if the SST is used with any gap between the cap and the
SST. Securely install the SST without any gaps.
1. Remove the fuel pump cap using the SST.
FUEL PUMP UNIT 310-069
aesffw00000051
01-14A–12
FUEL SYSTEM [L3]
Fuel pump cap installation note
Note
• If the gasket is stained with fuel, the fuel pump unit cannot be aligned at the specified position, when
tightening the cap. Make sure that the gasket is free of fuel.
1. Align the fuel tank and fuel pump unit alignment

marks as shown in the figure. FUEL TANK
ALIGNMENT MARK 01
FUEL PUMP UNIT

ALIGNMENT MARK
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2. Install the SST as shown in the figure.

3. Using the SST, tighten the fuel pump cap with the
specified tightening torque without shifting the
alignment marks.
• If the specified tightening torque cannot be
obtained, replace the fuel pump cap and
gasket.
• If the specified tightening torque cannot be
obtained after replacement of the fuel pump FUEL PUMP UNIT 310-069
cap and gasket, replace the fuel tank.
Fuel pump cap tightening torque

aesffw00000051
88.2—107.8 N·m {9.0—10.9 kgf·m, 65.1—79.5
ft·lbf}
End Of Sie
FUEL PUMP UNIT DISASSEMBLY/ASSEMBLY[L3]
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Note
• The fuel pump unit cannot be disassembled.
End Of Sie
FUEL PUMP UNIT INSPECTION[L3]
id0114a2801100
Continuity Inspection
2. Disconnect the fuel pump unit connector. (See 01-14A-10 FUEL PUMP UNIT REMOVAL/INSTALLATION[L3].)
3. Inspect for continuity between fuel pump unit
terminals C—D.
• If there is continuity, perform the Circuit Open/
Short Inspection. C A
• If there is no continuity, replace the fuel pump
unit. D B
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01-14A–13
FUEL SYSTEM [L3]
FUEL PUMP UNIT WIRING MAIN FUSE BLOCK
open or short circuit (Continuity check). HARNESS-SIDE CONNECTOR (FUEL PUMP RELAY)
B
C A
A E
D B FRONT
D
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Open circuit
— Fuel pump unit terminal C and fuel pump relay terminal E
— Fuel pump unit terminal D and body ground
Short circuit
— Fuel pump unit terminal C and body ground
— Fuel pump unit terminal D and power supply
Fuel Static Pressure Inspection
Note
• The fuel static pressure inspection cannot be performed because the pressure regulator is integrated with
the fuel pump unit.
End Of Sie
FUEL FILTER (HIGH-PRESSURE) REMOVAL/INSTALLATION[L3]
WM: FUEL FILTER (HIGH PRESSURE)
id0114a2803000
1. Perform the "Fuel Line Safety Procedure" referring to BEFORE SERVICE PRECAUTION. (See 01-14A-3
5. Inspect all related parts by performing AFTER SERVICE PRECAUTION. (See 01-14A-4 AFTER SERVICE
PRECAUTION[L3].)
1 Quick release connector
(See 01-14A-15 QUICK RELEASE CONNECTOR
2 Fuel filter (High-pressure) 1
End Of Sie
WM: QUICK RELEASE CONNECTOR
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01-14A–14
FUEL SYSTEM [L3]
QUICK RELEASE CONNECTOR REMOVAL/INSTALLATION[L3]
id0114a2801700
Warning
cause death or serious injury and damage. Fuel can also irritate skin and eyes. To prevent this,
always complete the "Fuel Line Safety Procedure", while referring to the BEFORE SERVICE
PRECAUTION.
Quick Release Connector Type 01

Caution
• There are three types of quick release connectors. Verify the type and location, and then remove/
install correctly.
FUEL TANK SIDE
ENGINE
COMPARTMENT
SIDE
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Type A Removal
1. Follow BEFORE SERVICE PRECAUTION to perform the "Fuel Line Safety Procedure" before servicing the fuel
system quick release connector, and wipe off the foreign material on the surface of the connecting area. (See
01-14A-3 BEFORE SERVICE PRECAUTION[L3].)
Caution
• The quick release connector may be damaged if the release tab is bent excessively. Do not expand
the release tab over the stopper.
Note
• The fuel hose can be removed by pushing forward the pipe side to release the lock.
01-14A–15
FUEL SYSTEM [L3]
2. Rotate the quick release connector release tab to
the stopper position.
RELEASE TAB
STOPPER
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3. Pull out the quick connector straight from the pipe

and disconnect it.
4. Cover the disconnected quick release connector
and pipe with vinyl sheeting or a similar material
to prevent it from becoming scratched or dirty.
FUEL PIPE FUEL HOSE
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Type A Installation
Note
• If the quick release connector O-ring is damaged or has slipped, replace the plastic hose.
• A checker tab is integrated with the quick
release connector for new fuel hoses and
evaporative hoses. Remove the checker tab CHECKER TAB
from the quick release connector after the
connector is completely engaged with the
fuel pipe.
1. Inspect the fuel hose and pipe sealing surface for

damage and deformation.
• If there is any malfunction, replace it with a NEW FUEL HOSE
new one.
2. Apply a small amount of clean engine oil to the
sealing surface of the pipe. atraaw00000852
3. Reconnect the fuel hose straight to the pipe until

a click is heard.
Note
• If the quick release connector does not move at all, disconnect it, verify that the O-ring is not damaged or
has not slipped, and then reconnect the quick release connector.
4. Lightly pull and push the quick release connector a few times by hand, and then verify that it can move (2—3
mm {0.079—0.118 in}) and is connected securely.
PRECAUTION[L3].)
Type B Removal
Caution
• Be careful not to damage the pipe when unlocking the retainer.
Note
• When a prompt connector is detached, following SST can be used.
— 49 N013 103A
— 310-041 (49 UN01 054)
— 49 E042 001
01-14A–16
FUEL SYSTEM [L3]
When using SST 49 N013 103A or 310-041 (49 UN01 054)
1. Follow “BEFORE SERVICE PRECAUTION” and remove dirt from the connecting surfaces before performing
any work operations. (See 01-14A-3 BEFORE SERVICE PRECAUTION[L3].)
2. Verify that the quick release connector joint area is free of foreign material. Clean if necessary.
3. Install the SST as shown in the figure and push
into the quick release connector to disconnect the QUICK RELEASE
CONNECTOR
fuel pipe.
and fuel pipe to prevent them from being
scratched or contaminated with foreign material.
01
49 N013 103A (FOR 8 mm {0.31 in}
JOINT PORT DIAMETER PIPE)
310-041 (FOR 9.5 mm {0.37 in}
49 UN01 054 DIAMETER PIPE)
atraaw00000239
When using SST 49 E042 001
Note
• If the quick release connector is removed, replace the retainer with a new one.
any work operations. (See 01-14A-3 BEFORE SERVICE PRECAUTION[L3].)
2. Set the SST parallel to the quick release
QUICK RELEASE CONNECTOR
connector. JOINT PORT
Note 49 E042 001

• The quick release connector can be
removed by pushing the center of the
retainer tabs.
• The retainer is attached to the pipe even
after the connector is disconnected.
3. Hold the center of the retainer tabs with the SST

ends and press the retainer.
atraaw00000250
4. Pull the connector side and disconnect the quick
release connector.
5. Raise a retainer tab using the SST and remove
the retainer.
49 E042 001
and fuel pipe with vinyl sheeting or a similar
material to prevent it from scratches or dirt.
R RETAINER
atraaw00000251
Type B Installation
Note
• Use only the designated genuine retainer when replacing the retainer.
1. Verify that the sealing surfaces of the fuel hose or fuel pipe have no damage or deformation. Replace if
necessary.
• If the O-ring of the quick release connector is damaged or displaced, replace the fuel hose.
2. Install a new retainer to the quick release connector, then visually verify that the retainer tab is installed
securely to the connector.
3. Apply a small amount of clean engine oil to the sealing surface of the fuel pipe.
01-14A–17
FUEL SYSTEM [L3]
4. Push the quick release connector into the fuel
pipe until a click is heard.
5. Lightly pull and push the quick release connector
a few times by hand, and then verify that it can NEW RETAINER
move 2.0—3.0 mm and is connected securely.
• If the quick release connector does not move
at all, verify that the O-ring is not damaged or
has slipped, and then reconnect the
connector.
End Of Sie
WM: FUEL INJECTOR
APPLY OIL TO THE SEALING SURFACE
atraaw00000242
FUEL INJECTOR REMOVAL/INSTALLATION[L3]

id0114a2800600
3. Disconnect the ignition coil connector.
4. Remove the fuel distributor cover.
PRECAUTION[L3].)
1 Quick release connector
20—26
(See 01-14A-15 QUICK RELEASE CONNECTOR {2.1—2.6, 2
REMOVAL/INSTALLATION[L3].) 15—19} 1
2 Fuel distributor
3 Injector clip R
(See 01-14A-18 Fuel Injector Removal Note.) 3
4 Fuel injector
(See 01-14A-19 Fuel Injector Installation Note.) R
OIL
OIL
4 R
atraaw00000853
Fuel Injector Removal Note
Caution
• The injector cannot be connected correctly with a deformed clip. It will also cause the injector to
rotate. Therefore, always replace the clip when the injector is removed.
1. Insert a flathead screwdriver between the injector

cup and clip finger. INSERT FLATHEAD
SCREWDRIVER.
INJECTOR CUP
PUSH
OUTWARD.
CLIP FINGER
CLIP
atraaw00000854
01-14A–18
FUEL SYSTEM [L3]
Note
• When pushing the clip finger outward,
deform the finger until it is detached
completely from the cup notch. CLIP FINGER
2. Push the clip finger outward using a flathead NOTCH

screwdriver and remove it from the injector cup.
3. Pull out the injector and clips.
4. Remove the clips from the fuel injector using the
01
following procedure:
(1) Hold the clip using pliers. atraaw00000855
(2) Pull the clips parallel to the injector groove

and remove them from the injector.
(3) Discard the clips.
PULL OUT PARALLEL.
INJECTOR GROOVE
atraaw00000856
Fuel Injector Installation Note

1. Apply a small amount of clean oil to the injector groove and a new O-ring.
2. Temporarily attach a new clip to the injector groove.
Note
• When the clip is installed correctly, the central area of the injector and the clip finger positions are aligned.
3. Hold the injector firmly and push the clip into the
injector until the clip stops sliding.
4. Verify the correct injector connector position, and
press the injector clips into the injector cup.
Continue pressing until the clip contacts the lower PRESS IN.
surface of the injector cup.
5. Verify that the injector and clips are correctly
installed with the clip locked onto the injector cup
notch.
End Of Sie
atraaw00000857
FUEL INJECTOR INSPECTION[L3]

id0114a2800700
4. Using a tester, inspect for the resistance between
fuel injector terminals A—B.
• If it is within the specification, inspect the
related harnesses. A
• If it is not within the specification, replace the B
fuel injector.
Fuel injector resistance

11.4—12.6 ohms [20 °C {68 °F}]
atraaw00000905
01-14A–19
FUEL SYSTEM [L3]
1. Disconnect the PCM connector. (See 01-40A-7
PCM REMOVAL/INSTALLATION[L3].) FUEL INJECTOR WIRING MAIN FUSE BLOCK
HARNESS SIDE CONNECTOR (MAIN RELAY)
B
A
A E
B FRONT
D
atraaw00000906
PCM
atraaw00000907
2. Inspect the following wiring harnesses for an open or short circuit (continuity check).
Open circuit
— Fuel injector No.1 terminal A and PCM terminal 2BB
— Fuel injector No.2 terminal A and PCM terminal 2BC
— Fuel injector No.3 terminal A and PCM terminal 2BD
— Fuel injector No.4 terminal A and PCM terminal 2AZ
— Fuel injector No.1 terminal B and main relay terminal A
Short circuit
• If there is continuity, the circuit is short. Repair or replace the harness.
— Fuel injector No.1 terminal B and body ground
Leakage Inspection
Warning
• Fuel line spills and leakage from the pressurized fuel system are dangerous. To prevent this,
complete the following inspection with the engine stopped.
3. Remove the fuel injector and fuel distributor as a single unit. (See 01-14A-18 FUEL INJECTOR REMOVAL/
INSTALLATION[L3].)
01-14A–20
FUEL SYSTEM [L3]
4. Fix the fuel injector to the fuel distributor with a
wire or the equivalent.
5. Connect the fuel hose.
Using PDS/IDS
01
atraaw00000908

fuel pump.
Caution
DLC-2
aesffw00000052

(FUEL PUMP RELAY)
B
A E
FRONT
D
atraaw00000837
7. Tilt the fuel injector at an angle of 42 ° to inspect

for leakage.
• If it is not within the specification, replace the
fuel injector.
Standard
1 drop or less/2 min

Using PDS/IDS
42˚
1. Stop the fuel pump using the "FP" simulation
function.
atraaw00000909
9. Remove the wire or equivalent securing the fuel injector.
10. Install the fuel injector. (See 01-14A-18 FUEL INJECTOR REMOVAL/INSTALLATION[L3].)
11. Inspect all parts by performing the AFTER REPAIR PROCEDURE. (See 01-14A-4 AFTER SERVICE
PRECAUTION[L3].)
01-14A–21
FUEL SYSTEM [L3]
Injection Volume Inspection
Warning
cause serious injury or death and damage. To prevent this, complete the following inspection with
the engine stopped.
1. Follow “BEFORE SERVICE PRECAUTION” before performing any work operations to prevent fuel from spilling
from the fuel system. (See 01-14A-3 BEFORE SERVICE PRECAUTION[L3].)
3. Remove the PCM.
4. Connect the PCM connector.
5. Remove the fuel injector and fuel distributor as a single unit. (See 01-14A-18 FUEL INJECTOR REMOVAL/
INSTALLATION[L3].)
7. Connect the corresponding fuel injector
connector.
Caution
ampjjw00001591

(FUEL PUMP RELAY)
10. Ground the following PCM terminals using a
jumper wire and measure the injection volume of
each fuel injector. B
Fuel injector No. PCM terminal A E

FRONT
1 2BB D
2 2BC
3 2BD
4 2AZ
atraaw00000837
PCM
atraaw00000907
• If not within the specification, replace the fuel injector.
Standard
66—85 ml {66—85 cc, 2.3—2.8 cu in}/15 s

Using PDS/IDS
1. Stop the fuel pump using the "FP" simulation function.
12. Remove the wire or the equivalent securing the fuel injector.
01-14A–22
FUEL SYSTEM [L3]
13. Install the fuel injector. (See 01-14A-18 FUEL INJECTOR REMOVAL/INSTALLATION[L3].)
14. Inspect all related parts by performing “AFTER SERVICE PRECAUTION”. (See 01-14A-4 AFTER SERVICE
PRECAUTION[L3].)
Atomization Inspection
1. Inspect the atomization status.
• If not normal, replace the fuel injector.
End Of Sie
01
WM: FUEL PUMP STOP SWITCH
NORMAL NOT NORMAL
atraaw00000910
FUEL PUMP STOP SWITCH REMOVAL/INSTALLATION[L3]

id0114a2802700
1. Remove the pin type retainer and the nut for the
cowl side trim panel.
2. Remove the cowl side trim panel.
NUT
COWL SIDE TRIM

PANEL
RETAINER
BUE114BWB060
3. Disconnect the fuel pump stop switch connector.

4. Remove the fuel pump stop switch.
5. Install the fuel pump stop switch.
FUEL PUMP STOP

SWITCH
BUE114BWB061
6. Verify that the release switch is pushed in.

RELEASE SWITCH
• If if is not pushed in, push in the release
switch securely.
7. Connect the fuel pump stop switch connector.
8. Install the cowl side trim panel.
End Of Sie
BUE114BWB062
01-14A–23
FUEL SYSTEM [L3]
FUEL PUMP STOP SWITCH INSPECTION[L3]
id0114a2802600
Operation Inspection
1. Remove the fuel pump stop switch. (See 01-14A-23 FUEL PUMP STOP SWITCH REMOVAL/
INSTALLATION[L3].)
2. Verify that release switch of the fuel pump stop RELEASE SWITCH
switch is pushed.
3. Lightly vibrate the fuel pump stop switch and
verify that the release switch does not pop out.
• If it pops out, replace the fuel pump stop
switch.
atraaw00001248
4. Shake the fuel pump stop switch hard and verify

RELEASE SWITCH
that the release switch pops out.
• If it does not pop out, replace the fuel pump
stop switch.
atraaw00001249
3. Inspect the resistance between the fuel pump
stop switch side terminals B—C.
• If the continuity is as indicated in the following
table, inspect the related wiring harness.
• If the continuity is not as indicated in the C B A
following table, replace the fuel pump stop
switch.
Release button Continuity
Pushed Continuity detected
Not pushed No continuity
01-14A–24
FUEL SYSTEM [AJ (3.0L Duratec)]
01-14B FUEL SYSTEM [AJ (3.0L Duratec)]

FUEL SYSTEM FLOW DIAGRAM FUEL INJECTOR INSPECTION
FUEL SYSTEM LOCATION INDEX FUEL CHARGING WIRING HARNESS
BEFORE SERVICE PRECAUTION [AJ (3.0L Duratec)] . . . . . . . . . . . . . . . . 01-14B–20
[AJ (3.0L Duratec)] . . . . . . . . . . . . . . . . 01-14B–4 FUEL DISTRIBUTOR
AFTER SERVICE PRECAUTION REMOVAL/INSTALLATION 01
FUEL LINE PRESSURE INSPECTION SHREDDER VALVE REMOVAL
[AJ (3.0L Duratec)] . . . . . . . . . . . . . . . . 01-14B–5 INSTALLATION[AJ (3.0L Duratec)]. . . . 01-14B–23
FUEL TANK REMOVAL/INSTALLATION FUEL PUMP STOP SWITCH
FUEL PUMP UNIT [AJ (3.0L Duratec)] . . . . . . . . . . . . . . . . 01-14B–23
REMOVAL/INSTALLATION FUEL PUMP STOP SWITCH
[AJ (3.0L Duratec)] . . . . . . . . . . . . . . . . 01-14B–7 INSPECTION[AJ (3.0L Duratec)] . . . . . 01-14B–24
FUEL PUMP UNIT INSPECTION PULSATION DAMPER INSPECTION
FUEL FILTER (HIGH-PRESSURE) PULSATION DAMPER
REMOVAL/INSTALLATION REMOVAL/INSTALLATION
QUICK RELEASE CONNECTOR FUEL FILLER PIPE
FUEL INJECTOR FUEL TANK STRAP
End of Toc
FUEL SYSTEM FLOW DIAGRAM[AJ (3.0L Duratec)]
NG: FUEL SYSTEM
id0114a1100300
FUEL INJECTOR
PULSATION DAMPER
FUEL FILLER CAP
FUEL FILTER
(HIGH-PRESSURE)
FUEL FILTER
(LOW-PRESSURE)
PRESSURE FUEL TANK

REGULATOR FUEL FLOW
FUEL PUMP UNIT

atraaw00003232
End Of Sie
WM: FUEL SYSTEM
01-14B–1
FUEL SYSTEM LOCATION INDEX[AJ (3.0L Duratec)]
id0114a1800100
Engine Compartment Side
2
1
atraaw00003253
Quick release connector Fuel pump stop switch

1 (See 01-14B-11 QUICK RELEASE CONNECTOR (See 01-14B-23 FUEL PUMP STOP SWITCH
REMOVAL/INSTALLATION[AJ (3.0L Duratec)].) 3 REMOVAL/INSTALLATION[AJ (3.0L Duratec)].)
Fuel injector (See 01-14B-24 FUEL PUMP STOP SWITCH
(See 01-14B-17 FUEL INJECTOR REMOVAL/ INSPECTION[AJ (3.0L Duratec)].)
2 INSTALLATION[AJ (3.0L Duratec)].) Pulsation damper
(See 01-14B-17 FUEL INJECTOR INSPECTION[AJ (See 01-14B-25 PULSATION DAMPER REMOVAL/
(3.0L Duratec)].) 4 INSTALLATION[AJ (3.0L Duratec)].)
(See 01-14B-24 PULSATION DAMPER
INSPECTION[AJ (3.0L Duratec)].)
5 Fuel pump relay
01-14B–2
Fuel Tank Side
4
01
2
atraaw00003364
Fuel tank Fuel filter (high pressure)

1 (See 01-14B-6 FUEL TANK REMOVAL/ 3 (See 01-14B-11 FUEL FILTER (HIGH-PRESSURE)
Fuel pump unit Quick release connector
(See 01-14B-7 FUEL PUMP UNIT REMOVAL/ 4 (See 01-14B-11 QUICK RELEASE CONNECTOR
2 INSTALLATION[AJ (3.0L Duratec)].) REMOVAL/INSTALLATION[AJ (3.0L Duratec)].)
(See 01-14B-10 FUEL PUMP UNIT
End Of Sie
01-14B–3
BEFORE SERVICE PRECAUTION[AJ (3.0L Duratec)]
id0114a1802000
Warning
skin and eyes. To prevent this, always perform the 'Fuel Line Safety Procedure'.
the vehicle body.
Caution
Fuel Line Safety Procedure

1. Remove the fuel-filler cap to release the pressure inside the fuel tank.
3. Start the engine.
4. After the engine stalls, repeat cranking for 2—3 times.
End Of Sie
AFTER SERVICE PRECAUTION[AJ (3.0L Duratec)]
id0114a1801900
Warning
also irritate skin and eyes. To prevent this, always perform the 'Fuel Line Safety Procedure'.
Fuel Leakage Inspection
Warning
also irritate skin and eyes. To prevent this, always carry out the following procedure with the
engine stopped.
Caution
• Fuel pump operation without fuel in the fuel tank may possible cause malfunction. Verify that there
is sufficient fuel in the tank for pump suction.

2. Using the simulation function “FP”, operate the
fuel pump.
3. Verify that there is no fuel leakage where work is
being performed while the fuel is pressurized.
• If there is leakage, replace the fuel hoses and
clips.
• If there is damage on the seal on the fuel pipe
side, replace the fuel pipe.
Standard
DLC-2
No leakage after 5 min.
aesffw00000035
4. After reinstallation, repeat step 1 to 3 in the fuel

leakage inspection.
End Of Sie
01-14B–4
FUEL LINE PRESSURE INSPECTION[AJ (3.0L Duratec)]
id0114a1800500
Warning
damage. Fuel can also irritate skin and eyes. To prevent this, complete the following inspection
with the engine stopped.
1. Perform the 'Fuel Line Safety Procedure' referring to the BEFORE SERVICE PRECAUTION. (See 01-14B-4
BEFORE SERVICE PRECAUTION[AJ (3.0L Duratec)].) 01
4. Disconnect the quick release connector of the engine compartment side. (See 01-14B-11 QUICK RELEASE
CONNECTOR REMOVAL/INSTALLATION[AJ (3.0L Duratec)].)
5. Turn the lever of the SST parallel to the hose as
49 N013 1A0C
LEVER
TO FUEL FROM FUEL TANK

DISTRIBUTOR
atraaw00001010
6. Insert the SST quick release connector into the

STRUT TOWER (LH)
fuel pipe until a click is heard.
7. Verify that the installation is secured by pulling the TO FUEL TANK
quick release connector.
8. Connect the negative battery cable. 49 N013 1A0C
10. Inspect the fuel pressure is within the LEVER
specification.
• If it is not within the specification, inspect for
the following and repair or replace any
malfunctioning parts. TO FUEL INJECTOR
Fuel pressure is lower than the
atraaw00001011
specification
— Fuel pump
— Fuel line leakage
— Fuel line clogging
Fuel pressure is higher than the specification
— Replace the pressure regulator
Fuel line pressure

420—460 kPa {4.3—4.6 kgf/cm2, 61—66 psi}
11. Turn the ignition switch to the LOCK position and measure the fuel pressure after 5 min.
• If it is not within the specification, inspect for the following and repair or replace any malfunctioning parts.
Zero or low
— Fuel pump
— Fuel line leakage
— Fuel line clogging
Fuel line hold pressure

Approx. 408 kPa {4.16 kgf/cm2, 59.1 psi} or more
BEFORE SERVICE PRECAUTION[AJ (3.0L Duratec)].)
13. Disconnect the SST.
14. Connect the quick release connector. (See 01-14B-11 QUICK RELEASE CONNECTOR REMOVAL/
15. Inspect all parts by performing the AFTER SERVICE PRECAUTION. (See 01-14B-4 AFTER SERVICE
PRECAUTION[AJ (3.0L Duratec)].)
End Of Sie
01-14B–5
FUEL TANK REMOVAL/INSTALLATION[AJ (3.0L Duratec)]
WM: FUEL TANK
id0114a1801600
Warning
• Fuel is very flammable liquid. If fuel spills or leaks from the pressurized fuel system, it will cause
serious injury or death and facility breakage. Fuel can also irritate skin and eyes. To prevent this,
always complete the "Fuel Line Safety Procedure", while referring to "BEFORE SERVICE
PRECAUTION".
• Repairing a fuel tank that has not been properly steam cleaned can be dangerous. Explosion or
fire may cause death or serious injury. Always properly steam clean a fuel tank before repairing it.
vehicle body.
1. Park the vehicle on a level surface.

2. Complete the BEFORE SERVICE PRECAUTION. (See 01-14B-4 BEFORE SERVICE PRECAUTION[AJ (3.0L
Duratec)].)
4. Remove the fuel pump unit. (See 01-14B-7 FUEL PUMP UNIT REMOVAL/INSTALLATION[AJ (3.0L Duratec)].)
5. Drain the fuel from the service hole.
6. Remove the rear wheel (LH).
7. Remove the rivets and the fuel filler pipe shield.
atraaw00000988
8. Disconnect the fuel tank filler hose and the fuel

tank filler vent hose from the fuel filler pipe.
9. Remove the silencer.
10. Remove the propeller shaft.
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11. Remove the differential mounting installation bolt.
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01-14B–6
12. Remove the differential-to-bracket bolts.
13. Loosen the differential mounting bracket BRACKET BOLT
installation bolts, rotate the brackets and position
the axle rearward.
14. Use a suitable jack to support the fuel tank.
01
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15. Disconnect the vapor hose.

16. Remove the fuel tank strap. (See 01-14B-26
FUEL TANK STRAP REMOVAL/ VAPOR HOSE
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17. Lower and remove the fuel tank.

Differential mounting bracket installation bolt FUEL TANK

tightening torque
127.5—172.5 N·m {13.01—17.59 kgf·m,
94.04—127.2 ft·lbf}
Bracket bolt tightening torque
68—92 N·m {7.0—9.3 kgf·m, 51—67 ft·lbf}
End Of Sie
WM: FUEL PUMP
atraaw00000993
FUEL PUMP UNIT REMOVAL/INSTALLATION[AJ (3.0L Duratec)]

id0114a1800900
Warning
Safety Procedure”.
damage. Fuel can also irritate skin and eyes. To prevent this, before performing the fuel pump unit
removal/installation, always complete the “Fuel Leak Inspection After Fuel Pump Unit
Installation”.
vehicle body.
Caution
• Because the fuel tank is constructed such that the fuel level is higher than the installation surface
of the fuel pump, fuel leakage could occur. If the fuel gauge indicates a fuel level of half or more,
perform the following Steps 1-8 to drain approx. 10 L {11 US gal, 8.8 lmp gal} of fuel.
• Disconnecting/connecting the quick release connector without cleaning it may possibly cause
damage to the fuel pipe and quick release connector. Always clean the quick release connector
joint area before disconnecting/connecting using a cloth or soft brush, and make sure that it is
free of foreign material.
• To prevent the SST from coming off the fuel pump cap while performing the work, always perform
the removal/installation procedure with 2 people. One person presses the SST against cap from
directly above, while the other person rotates the SST.
01-14B–7
(3.0L Duratec)].)
2. Lift the rear seat cushion (LH).
3. Remove the scuff plate and turn over the carpet.
4. Remove the service hole cover.
SERVICE HOLE COVER
atraaw00000149
5. Disconnect the quick release connector as shown

in the figure. QUICK RELEASE
CONNECTOR
FRONT
LH REAR DOOR
aesffw00000046
6. Connect a hose to the fuel pump unit.

7. Drain the fuel into a container used for collecting
gasoline.
8. Start the fuel pump using the following procedure. HOSE
FRONT
LH REAR DOOR
aesffw00000047
01-14B–8
Using PDS/IDS
fuel pump.
Caution
01
DLC-2
aesffw00000036

terminals B and D in the main fuse block. MAIN FUSE BLOCK
(FUEL PUMP RELAY)
operate the fuel pump. B
Caution A E
• The fuel pump could be damaged if it is
operated (fuel pump idling) while there is FRONT D
no fuel in the fuel tank. Verify the amount
of fuel being discharged from the hose
and stop operation of the fuel pump
when essentially no fuel is being
atraaw00000953
discharged.

10. Remove the fuel-filler cap.
FUEL-FILLER CAP
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11. Remove the fuel pump unit using the SST.
Note
Fuel pump unit tightening torque FUEL PUMP UNIT

88.2—107.8 N·m {9.0—10.9 kgf·m, 65.1—79.5
ft·lbf} 310-069
13. Complete the “AFTER SERVICE PRECAUTION”.

aesffw00000042
(See 01-14B-4 AFTER SERVICE
End Of Sie
01-14B–9
FUEL PUMP UNIT INSPECTION[AJ (3.0L Duratec)]
id0114a1801100
Warning
always complete the "Fuel Line Safety Procedure", while referring to "BEFORE SERVICE
PRECAUTION".
before performing the fuel pump unit removal/installation, always complete the "Fuel Leak
Inspection After Fuel Pump Unit Installation".
vehicle body.
2. Disconnect the fuel pump unit connector. (See 01-14A-10 FUEL PUMP UNIT REMOVAL/INSTALLATION[L3].)
3. Inspect for continuity between fuel pump unit
terminals C—D.
• If there is continuity, perform the Circuit Open/
Short Inspection. C A
• If there is no continuity, replace the fuel pump
unit. D B
atraaw00002278

2. Inspect the following wiring harness for open or FUEL PUMP UNIT
short (continuity check). WIRING HARNESS-SIDE CONNECTOR
C A
D B
atraaw00000111
Open circuit
— Fuel pump unit terminal C and fuel pump relay terminal E
— Fuel pump unit terminal D and body ground
Short circuit
— Fuel pump unit terminal C and body ground
— Fuel pump unit terminal D and power supply
Note
• The fuel static pressure inspection cannot be performed because the pressure regulator is integrated with
the fuel pump unit.
End Of Sie
WM: FUEL FILTER (HIGH PRESSURE)
01-14B–10
FUEL FILTER (HIGH-PRESSURE) REMOVAL/INSTALLATION[AJ (3.0L Duratec)]
id0114a1803000
Warning
always complete the "Fuel Line Safety Procedure", while referring to the "BEFORE SERVICE
PRECAUTION".
Caution 01
1. Perform the fuel line safety procedure. (See 01-14B-4 BEFORE SERVICE PRECAUTION[AJ (3.0L Duratec)].)
Note
• Place an appropriate container under the fuel filter (high-pressure).
3. Disconnect the fuel hose from the fuel filter (high-pressure). (See 01-14B-11 QUICK RELEASE CONNECTOR
4. Loosen the clamp and remove the fuel filter (high-
pressure).
Note
• If the fuel hose is removed, replace the quick
connector retainer with a new one.

End Of Sie
FUEL FILTER
(HIGH-PRESSURE)
atraaw00000114
QUICK RELEASE CONNECTOR REMOVAL/INSTALLATION[AJ (3.0L Duratec)]

id0114a1801700
Warning
PRECAUTION".
Caution
01-14B–11
Quick Release Connector Type
Caution
• There are three types of quick release connector. Verify the type and location, and then remove/
install correctly.
ENGINE
COMPARTMENT SIDE
FUEL TANK SIDE
TYPE A
TYPE B
TYPE C
atraaw00003231
Type A
Removal
3. Remove the fuel line clip.
atraaw00000227
4. Install the SST.

310-D005
(49 UN01 052)
atraaw00000228
01-14B–12
5. Close the SST and insert it into the openside of
the cage. 310-D005
(49 UN01 052)
01
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6. Remove the quick release connector.

310-D005
(49 UN01 052)
atraaw00000230
7. Remove the SST.

310-D005
(49 UN01 052)
atraaw00000231
Installation
1. Verify that there is no damage or deformation on
the sealing surface of the fuel hose and fuel
distributor, and replace any malfunctioning part if
necessary.
• If there is damage or misalignment on the O-
ring inside the quick release connector,
replace the fuel hose.
2. Apply clean engine oil to the O-ring.
atraaw00000232
01-14B–13
3. Fit the male side quick release connector into the
female quick release connector end and push
until the garter spring snaps over the flared end of
the female quick release connector.
atraaw00000233
4. Verify the connector engagement by pulling on

the quick release connector.
atraaw00000234
5. Install the fuel line clip.

atraaw00000235
Type B
Removal
2. Remove the battery cover.
4. Depress the quick release connector tabs.
5. Remove the quick release connector.
RELEASE TAB
atraaw00000236
01-14B–14
Installation
1. Clean and inspect the quick release connector and the fuel pipe for damage.
2. Align the fuel pipe to the quick release connector
and push until you hear a click.
Note
• If the quick release connector retainer of the
fuel line is removed, replace it with a new
one. 01
atraaw00000237
3. Pull on the quick release connector to make sure

it is fully engaged.
atraaw00000238
Type C
Removal
Caution
• Be careful not to damage the pipe when unlocking the retainer.
Note
• When a prompt connector is detached, following SST can be used.
— 49 N013 103A
— 310-041 (49 UN01 054)
— 49 E042 001
When using SST 49 N013 103A or 310-041 (49 UN01 054)

any work operations. (See 01-14B-4 BEFORE SERVICE PRECAUTION[AJ (3.0L Duratec)].)
3. Verify that the quick release connector joint area is free of foreign material. Clean if necessary.
4. Install the SST as shown in the figure and push
into the quick release connector to disconnect the QUICK RELEASE
CONNECTOR
fuel pipe.
and fuel pipe to prevent them from being
scratched or contaminated with foreign material.
49 N013 103A (FOR 8 mm {0.31 in}

JOINT PORT DIAMETER PIPE)
310-041 (FOR 9.5 mm {0.37 in}
49 UN01 054 DIAMETER PIPE)
atraaw00000239
01-14B–15
When using SST 49 E042 001
Note
• If the quick release connector is removed, replace the retainer with a new one.
any work operations. (See 01-14B-4 BEFORE SERVICE PRECAUTION[AJ (3.0L Duratec)].)
3. Set the SST parallel to the quick release
QUICK RELEASE CONNECTOR
connector. JOINT PORT
Note 49 E042 001

• The quick release connector can be
removed by pushing the center of the
retainer tabs.
• The retainer is attached to the pipe even
after the connector is disconnected.
4. Hold the center of the retainer tabs with the SST

ends and press the retainer.
atraaw00000250
5. Pull the connector side and disconnect the quick
release connector.
6. Raise a retainer tab using the SST and remove
the retainer.
49 E042 001
and fuel pipe with vinyl sheeting or a similar
material to prevent it from scratches or dirt.
R RETAINER
atraaw00000251
Installation
Note
• Use only the designated genuine retainer when replacing the retainer.
1. Verify that the sealing surfaces of the fuel hose or fuel pipe have no damage or deformation. Replace if
necessary.
• If the O-ring of the quick release connector is damaged or displaced, replace the fuel hose.
2. Install a new retainer to the quick release connector, then visually verify that the retainer tab is installed
securely to the connector.
3. Apply a small amount of clean engine oil to the sealing surface of the fuel pipe.
4. Push the quick release connector into the fuel
pipe until a click is heard.
5. Lightly pull and push the quick release connector
a few times by hand, and then verify that it can NEW RETAINER
move 2.0—3.0 mm and is connected securely.
• If the quick release connector does not move
at all, verify that the O-ring is not damaged or
has slipped, and then reconnect the
connector.
End Of Sie
WM: FUEL INJECTOR
APPLY OIL TO THE SEALING SURFACE
atraaw00000242
01-14B–16
FUEL INJECTOR REMOVAL/INSTALLATION[AJ (3.0L Duratec)]
id0114a1800600
Warning
PRECAUTION".
1. Disconnect the negative battery cable. 01

2. Remove the fuel distributor. (See 01-14B-22 FUEL DISTRIBUTOR REMOVAL/INSTALLATION[AJ (3.0L
Duratec)].)
3. Remove the fuel injector from the fuel distributor.
FUEL DISTRIBUTOR
FUEL INJECTOR
atraaw00001012
4. Apply clean engine oil to a new O-ring sealing.

5. Install in the reverse order of removal. O-RING SEAL
End Of Sie
atraaw00001013
FUEL INJECTOR INSPECTION[AJ (3.0L Duratec)]

id0114a1800700
Leakage Inspection
Warning
• Fuel line spills and leakage from the pressurized fuel system are dangerous. To prevent this,
complete the following inspection with the engine stopped.
BEFORE SERVICE PRECAUTION[AJ (3.0L Duratec)].)
3. Remove the fuel injector and fuel distributor as a single unit. (See 01-14B-17 FUEL INJECTOR REMOVAL/
5. Connect the fuel hose.
7. Turn the ignition switch to the ON position.
atraaw00000115
01-14B–17
9. Using the “FP” simulation function, verify the fuel
pump operation sound when the fuel pump relay
is turned from off to on.
DLC-2
aesffw00000038
10. Tilt the fuel injectors 60 ° and inspect for the fuel
leakage.
fuel injector.
• If the monitor item condition/specification
(reference) is not within the specification,
even though there is no malfunction, perform
the 'Circuit Open/Short Inspection'.
Standard 60°
1 drop or less/2 min
atraaw00000117
11. Turn the ignition switch to the LOCK position and
stop the fuel pump.
12. Inspect all parts by performing the AFTER SERVICE PRECAUTION. (See 01-14B-4 AFTER SERVICE
4. Using a tester, inspect for the resistance between fuel injector terminals A—B.
• If it is within the specification, inspect the related harnesses.
• If it is not within the specification, replace the fuel injector.
Fuel injector resistance standard

13.1—14.5 ohms [20°C]
01-14B–18
FUEL INJECTOR
MAIN FUSE BLOCK
(FUEL PUMP RELAY)
B
A
A
01
B
E
FRONT D
PCM
26 25 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
52 51 50 49 48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27
78 77 76 75 74 73 72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53
104103102 101100 99 98 97 96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79
atraaw00002132
Open circuit
— Fuel injector NO.1 terminal B and main relay terminal B
— Fuel injector NO.1 terminal A and PCM terminal 75
Short circuit
— Fuel injector NO.1 terminal B and body GND
— Fuel injector NO.1 terminal A and power supply
End Of Sie
WM: FUEL SYSTEM
01-14B–19
FUEL CHARGING WIRING HARNESS REMOVAL/INSTALLATION[AJ (3.0L Duratec)]
id0114a1802200
Warning
PRECAUTION".
Duratec)].)
atraaw00000206
3. Disconnect the condenser connector.
atraaw00000207
4. Disconnect the engine coolant temperature (ECT)

sensor connector.
atraaw00000208
5. Disconnect the 16-pin connectors.
atraaw00000209
01-14B–20
6. Disconnect the power steering pressure (PSP)
switch connector.
01
atraaw00000210
7. Disconnect the fuel injector connectors and

release the wiring harness locators from the fuel
distributor.
atraaw00000211
8. Disconnect the camshaft position (CMP) sensor

connector.
9. Remove the tire and wheel
atraaw00000212
10. Remove the lower splash shield
atraaw00000353
11. Disconnect the crankshaft position (CKP) sensor

connector.
atraaw00000214
01-14B–21
12. Disconnect the oil pressure switch connector.
14. Remove the fuel charging wiring harness from the
vehicle.
End Of Sie
WM: FUEL DISTRIBUTOR
atraaw00000215
FUEL DISTRIBUTOR REMOVAL/INSTALLATION[AJ (3.0L Duratec)]

id0114a1802400
Warning
PRECAUTION".
Duratec)].)
2. Disconnect the fuel line. (See 01-14B-11 QUICK RELEASE CONNECTOR REMOVAL/INSTALLATION[AJ
(3.0L Duratec)].)
3. Disconnect the six fuel injector connectors and
position the wiring harness away from the fuel
distributor.
atraaw00001014
4. Remove the vacuum hose.

FUEL DISTRIBUTOR
5. Remove the fuel distributor.
Note
• Apply clean engine oil to the fuel injector.
Fuel distributor installation bolt tightening

torque
8—12 N·m {82—122 kgf·cm, 71—106 lbf·in}
VACUUM HOSE
atraaw00001015
End Of Sie
01-14B–22
SHREDDER VALVE REMOVAL INSTALLATION[AJ (3.0L Duratec)]
id0114a1802500
1. Release the fuel pressure. (See 01-14B-4 BEFORE SERVICE PRECAUTION[AJ (3.0L Duratec)].)
2. Remove the shredder valve.
End Of Sie
WM: FUEL PUMP STOP SWITCH
SHREDDER VALVE
01
aesffw00000457
FUEL PUMP STOP SWITCH REMOVAL/INSTALLATION[AJ (3.0L Duratec)]

id0114a1802700
1. Remove the pin-type retainer and the nut for the
cowl side trim panel.
2. Remove the cowl side trim panel.
NUT
COWL SIDE TRIM

PANEL
RETAINER
BUE114BWB060

4. Remove the fuel pump stop switch.
5. Install the fuel pump stop switch.
6. Verify that the release switch is pushed in.
FUEL PUMP STOP

SWITCH
BUE114BWB061
• If it is not pushed in, push in the release

RELEASE SWITCH
switch securely.
7. Connect the fuel pump stop switch connector.
8. Install the cowl side trim panel.
End Of Sie
BUE114BWB062
01-14B–23
FUEL PUMP STOP SWITCH INSPECTION[AJ (3.0L Duratec)]
id0114a1802600
Operation Inspection
1. Remove the fuel pump stop switch. (See 01-14B-23 FUEL PUMP STOP SWITCH REMOVAL/
2. Verify that release switch of the fuel pump stop RELEASE SWITCH
switch is pushed.
3. Hit the fuel pump stop switch slightly and verify
that the release switch does not pop up.
• If it pops up, replace the fuel pump stop
switch.
atraaw00000118
4. Shake the fuel pump stop switch hard and verify

RELEASE SWITCH
that the release switch pops up.
• If it does not pop up, replace the fuel pump
stop switch.
atraaw00000119
3. Inspect the resistance between the fuel pump
stop switch side terminals B—C.
• If the continuity is as indicated in the following
table, inspect the related wiring harness.
• If the continuity is not as indicated in the C B A
following table, replace the fuel pump stop
switch.
Release button Continuity
Pushed Continuity detected
Not pushed No continuity
End Of Sie
WM: PULSATION DAMPER
atraaw00001265
PULSATION DAMPER INSPECTION[AJ (3.0L Duratec)]

id0114a1802800
1. Visually inspect the pulsation damper for damage and cranks. Also inspect if there is no extreme rust which will
cause fuel leakage.
• If either is observed, replace the pulsation damper. (See 01-14B-25 PULSATION DAMPER REMOVAL/
End Of Sie
01-14B–24
PULSATION DAMPER REMOVAL/INSTALLATION[AJ (3.0L Duratec)]
id0114a1802900
Duratec)].)
2. Disconnect the vacuum hose.
3. Remove the snap ring. PULSATION DAMPER
4. Remove the pulsation damper.
VACUUM HOSE
Caution
• Since the general O-ring sealing could 01
cause fuel leakage, always use genuine
O-ring sealing.
SNAP RING
aesffw00000458
5. Remove the O-ring sealing and replace with a

new one.
• Apply a small amount of clean engine oil to
the O-ring sealing.
End Of Sie
WM: FUEL TANK
O-RING SEAL
aesffw00000459
FUEL FILLER PIPE REMOVAL/INSTALLATION[AJ (3.0L Duratec)]

id0114a1803100
Warning
PRECAUTION".
1. Remove the rear wheel (LH).

2. Remove the fuel-filler cap.
FUEL-FILLER CAP
atraaw00000126
3. Remove the filler neck retaining screws.
atraaw00000127
01-14B–25
4. Remove the rivets and the fuel filler pipe shield.
atraaw00000128
5. Disconnect the breather hose and joint hose.

6. Remove the fuel-filler pipe.
BREATHER HOSE
Fuel filler pipe installation bolt tightening
torque JOINT HOSE
8.82—12.24 N·m {90.0—124.8 kgf·cm, 78.1—
108.3 in·lbf}
Filler neck retaining installation screw

tightening torque
2.5—3.5 N·m {26—35 kgf·cm, 23—30 in·lbf}
atraaw00000129
End Of Sie
FUEL TANK STRAP REMOVAL/INSTALLATION[AJ (3.0L Duratec)]
id0114a1803300
2. Use a suitable jack to support the fuel tank.
3. Disconnect the pin-type retainer from the fuel tank
strap and position the parking brake cable aside.
atraaw00001002
4. Remove the bolts and the fuel tank straps.

Fuel tank strap installation bolt tightening

torque
43—61 N·m {4.4—6.2 kgf·m, 32—44 ft·lbf}
End Of Sie
atraaw00001003
01-14B–26
EXHAUST SYSTEM [L3]
01-15A EXHAUST SYSTEM [L3]

EXHAUST SYSTEM INSPECTION EXHAUST SYSTEM
[L3] . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-15A–1 REMOVAL/INSTALLATION[L3] . . . . . . . 01-15A–2
End of Toc
EXHAUST SYSTEM INSPECTION[L3]
WM: EXHAUST SYSTEM
id0115a2800100
1. Start the engine and inspect each exhaust system component for exhaust gas leakage. 01
• If leakage is found, repair or replace if necessary.
End Of Sie
01-15A–1
EXHAUST SYSTEM [L3]
EXHAUST SYSTEM REMOVAL/INSTALLATION[L3]
id0115a2800200
Warning
• A hot engine and exhaust system can cause severe burns. Turn off the engine and wait until they
are cool before removing the exhaust system.

7.8—10.8 N·m {80—110 kgf·cm, 69—95 in·lbf}
43—64 5 SST
{4.4—6.5, 32—47} 29—49
{3.0—4.9, A
22—36}
R
6 R
7 38—51
{3.9—5.2, 2
29—37}
38—51
{3.9—5.2,
38—51
29—37}
39—46 {3.9—5.2,
{4.0—4.6, 29—37}
29—33}
SST
4
1
29—49 3
{3.0—4.9,
22—36}
R
R 38—51 {3.9—5.2, 29—37}
38—51
{3.9—5.2, 29—37}
A
R N·m {kgf·m, ft·lbf}
atraaw00001123
1 After-silencer 6 Exhaust manifold insulator

2 Main silencer (See 01-15A-4 Exhaust Manifold Insulator
Installation Note.)
3 Rear HO2S
(See 01-15A-3 HO2S Removal Note.) 7 Exhaust manifold
(See 01-15A-4 Exhaust Manifold Installation Note.)
4 TWC
(See 01-15A-3 TWC Removal Note.) 8 Exhaust manifold bracket
(See 01-15A-3 Exhaust Manifold Bracket Installation
5 Front HO2S Note.)
(See 01-15A-3 HO2S Removal Note.)
01-15A–2
EXHAUST SYSTEM [L3]
HO2S Removal Note
1. Remove the HO2S using the SST.
49 L018 001
01
ampjjw00001053
TWC Removal Note

1. Remove the transverse member. (See 02-13-9 FRONT CROSSMEMBER REMOVAL/INSTALLATION.)
2. Remove the splash shield.
3. Remove the under cover.
4. Remove the TWC.
Exhaust Manifold Bracket Installation Note

1. Tighten the exhaust manifold bracket No.1
installation bolts shown in the figure.
Exhaust manifold bracket No.1 installation

bolt tightening torque EXHAUST MANIFOLD
39—46 N·m {4.0—4.6 kgf·m, 29—33 ft·lbf} BRACKET NO.1
atraaw00002310
2. Temporarily tighten the exhaust manifold bracket

No.2 installation bolts shown in the figure.
3. Install the exhaust manifold. (See 01-15A-4
Exhaust Manifold Installation Note.)
EXHAUST MANIFOLD
BRACKET NO.2
atraaw00002311
01-15A–3
EXHAUST SYSTEM [L3]
4. Temporarily tighten the No.1 shown in the figure.
5. Tighten the No.1 shown in the figure.

bolt tightening torque
38—51 N·m {3.9—5.2 kgf·m, 29—37 ft·lbf}
6. Tighten the No.2 shown in the figure. 1

bolt tightening torque
38—51 N·m {3.9—5.2 kgf·m, 29—37 ft·lbf}
atraaw00002312
Exhaust Manifold Installation Note

1. Temporarily tighten the exhaust manifold installation bolts.
2. Tighten the exhaust manifold installation bolts in
the order shown in the figure.
4 1 6
Exhaust manifold installation bolt tightening
torque
43—64 N·m {4.4—6.5 kgf·m, 32—47 ft·lbf}
7 5 2 3
atraaw00000916
Exhaust Manifold Insulator Installation Note

1. Temporarily tighten the exhaust manifold insulator installation bolts.
2. Tighten the exhaust manifold insulator installation
bolts in the order shown in the figure.
2 1
Exhaust manifold insulator installation bolts
tightening torque
7.8—10.8 N·m {80—110 kgf·cm, 69—95
in·lbf}
End Of Sie
4 3
atraaw00001124
01-15A–4
EXHAUST SYSTEM [AJ (3.0L Duratec)]
01-15B EXHAUST SYSTEM [AJ (3.0L Duratec)]

EXHAUST SYSTEM LOCATION INDEX MAIN SILENCER
EXHAUST SYSTEM INSPECTION [AJ (3.0L Duratec)] . . . . . . . . . . . . . . . . 01-15B–3
[AJ (3.0L Duratec)] . . . . . . . . . . . . . . . . 01-15B–1 PRESILENCER
EXHAUST MANIFOLD REMOVAL/INSTALLATION
[AJ (3.0L Duratec)] . . . . . . . . . . . . . . . . 01-15B–2 FRONT PIPE 01
REMOVAL/INSTALLATION
[AJ (3.0L Duratec)] . . . . . . . . . . . . . . . . 01-15B–4
End of Toc
EXHAUST SYSTEM LOCATION INDEX[AJ (3.0L Duratec)]
WM: EXHAUST SYSTEM
id0115a1801200
4
2
1
atraaw00003369
Exhaust manifold (LH) Presilencer

1 (See 01-15B-2 EXHAUST MANIFOLD REMOVAL/ 4 (See 01-15B-4 PRESILENCER REMOVAL/
Exhaust manifold (RH) Catalytic converter
2 (See 01-15B-2 EXHAUST MANIFOLD REMOVAL/ 5 (See 01-16B-9 CATALYTIC CONVERTER
Main silencer
3 (See 01-15B-3 MAIN SILENCER REMOVAL/
End Of Sie
EXHAUST SYSTEM INSPECTION[AJ (3.0L Duratec)]
id0115a1800100
1. Start the engine and inspect each exhaust system component for exhaust gas leakage.
• If there is leakage, repair or replace the appropriate component.
End Of Sie
01-15B–1
EXHAUST MANIFOLD REMOVAL/INSTALLATION[AJ (3.0L Duratec)]
id0115a1800400
Exhaust Manifold (LH) Removal/Installation
2. Remove the front and rear heated oxygen sensor
(HO2S) (LH). (See 01-40B-26 FRONT HEATED
OXYGEN SENSOR (HO2S) REMOVAL/
INSTALLATION[AJ (3.0L Duratec)].) (See 01-
40B-30 REAR HEATED OXYGEN SENSOR
(HO2S) REMOVAL/INSTALLATION[AJ (3.0L
Duratec)].)
atraaw00000354
3. Remove the exhaust front pipe and slide aside.

EXHAUST FRONT PIPE
4. Remove the drive belt and slide aside.
B
A
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5. Remove the A/C compressor bolts and slide

aside.
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6. Remove the exhaust manifold (LH) and dispose of

the gasket.
A/C compressor installation bolt tightening

torque
20—30 N·m {2.1—3.0 kgf·m, 15—22 ft·lbf}
Exhaust front pipe installation bolt tightening
torque
A: 40.3—54.7 N·m {4.11—5.57 kgf·m, 29.8—
40.3 ft·lbf}
B: 38.0—51.0 N·m {3.88—5.20 kgf·m, 28.0—
atraaw00000357
37.6 ft·lbf}
Splash shield installation bolt tightening
torque
8.9—12.7 N·m {90—130 kgf·cm, 67.8—112 in·lbf}
01-15B–2
Exhaust Manifold (LH) Installation Note
1. Position the new gasket and tighten the exhaust
manifold (LH) nuts in the order indicated in the 1 4
figure.
Exhaust manifold (LH) installation nut

tightening torque 5 6
19.1—25.9 N·m {1.95—2.64 kgf·m, 14.1—19.1
ft·lbf}
3
01
2
atraaw00000358
Exhaust Manifold (RH) Removal/Installation

1. Remove the PCM wiring harness protector connecting bolt and position it out of the way.
2. Remove the exhaust gas recirculation (EGR) tube. (See 01-16B-7 EGR PIPE REMOVAL/INSTALLATION[AJ
(3.0L Duratec)].)
3. Remove the generator. (See 01-17B-4 GENERATOR REMOVAL/INSTALLATION[AJ (3.0L Duratec)].)
4. Remove the front HO2S (RH). (See 01-40B-26 FRONT HEATED OXYGEN SENSOR (HO2S) REMOVAL/
5. Remove the exhaust manifold (RH) and dispose
of the gasket.
atraaw00000359
Exhaust Manifold (RH) Installation Note

1. Position the new gasket and tighten the exhaust
manifold (RH) nuts in the order indicated in the 6 4 1 2 3 5
figure.
Exhaust manifold (RH) installation nut

tightening torque
19.1—25.9 N·m {1.95—2.64 kgf·m, 14.1—19.1
ft·lbf}
End Of Sie
atraaw00000360
MAIN SILENCER REMOVAL/INSTALLATION[AJ (3.0L Duratec)]

id0115a1800700
2. Remove the U-shaped bolt.
3. Remove the silencer.
• Dispose of the gasket.
• Dispose of the nuts.
atraaw00002091
01-15B–3
• Install a new gasket.
• Install new nuts.
Nut tightening torque

40.3—54.7 N·m {4.11—5.57 kgf·m, 29.8—40.3
ft·lbf}
U-shaped bolt tightening torque
40.3—54.7 N·m {4.11—5.57 kgf·m, 29.8—40.3
ft·lbf}
PRESILENCER REMOVAL/INSTALLATION[AJ (3.0L Duratec)]

id0115a1800600
2. Remove and discard the nuts.
3. Detach the presilencer from the hanger and
remove.
atraaw00002089


40.3—54.7 N·m {4.11—5.57 kgf·m, 29.8—40.3
ft·lbf}
End Of Sie
PRESILENCER
atraaw00002090
FRONT PIPE REMOVAL/INSTALLATION[AJ (3.0L Duratec)]

id0115a1800500
3. Remove the rear heated oxygen sensor (HO2S) (RH). (See 01-40B-30 REAR HEATED OXYGEN SENSOR
(HO2S) REMOVAL/INSTALLATION[AJ (3.0L Duratec)].)
4. Remove the transverse member.
5. Remove the two nuts and dispose of them.
FRONT PIPE
6. Detach the flexible Y-shaped pipe from the
exhaust manifold. B
7. Remove the nuts and dispose of them.
atraaw00003251
01-15B–4
8. Remove the nuts.
01
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FRONT PIPE
A
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9. Detach the front pipe from the hanger and

remove.
• Install the new nuts.
Exhaust front pipe installation bolt tightening

torque
A: 40.3—54.7 N·m {4.11—5.57 kgf·m, 29.8—
40.3 ft·lbf}
B: 38.0—51.0 N·m {3.88—5.20 kgf·m, 28.0—
37.6 ft·lbf}
atraaw00002111
40.3—54.7 N·m {4.11—5.57 kgf·m, 29.8—40.3
ft·lbf}
End Of Sie
01-15B–5
EMISSION SYSTEM [L3]
01-16A EMISSION SYSTEM [L3]

EMISSION SYSTEM LOCATION INDEX EGR VALVE REMOVAL/INSTALLATION
[L3] . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-16A–1 [L3] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-16A–5
EMISSION SYSTEM DIAGRAM[L3] . . . . 01-16A–2 EGR VALVE INSPECTION[L3]. . . . . . . . . 01-16A–6
CHARCOAL CANISTER POSITIVE CRANKCASE
REMOVAL/INSTALLATION[L3] . . . . . . 01-16A–3 VENTILATION (PCV) VALVE
CHARCOAL CANISTER INSPECTION INSPECTION[L3] . . . . . . . . . . . . . . . . . . 01-16A–7
[L3] . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-16A–4 CATCH TANK INSPECTION[L3] . . . . . . . 01-16A–7 01
PURGE SOLENOID VALVE ROLLOVER VALVE
REMOVAL/INSTALLATION[L3] . . . . . . 01-16A–4 REMOVAL/INSTALLATION[L3] . . . . . . . 01-16A–7
PURGE SOLENOID VALVE ROLLOVER VALVE INSPECTION[L3]. . . 01-16A–8
INSPECTION[L3] . . . . . . . . . . . . . . . . . 01-16A–4
End of Toc
EMISSION SYSTEM LOCATION INDEX[L3]
WM: EMISSION SYSTEM
id0116a2803700
Engine compartment side
2
3
atraaw00000591
1 Purge solenoid valve 3 EGR valve

(See 01-16A-4 PURGE SOLENOID VALVE (See 01-16A-5 EGR VALVE REMOVAL/
2 Catch tank (Built into air cleaner) (See 01-16A-6 EGR VALVE INSPECTION[L3].)
(See 01-16A-7 CATCH TANK INSPECTION[L3].) 4 PCV valve
(See 01-16A-7 POSITIVE CRANKCASE
VENTILATION (PCV) VALVE INSPECTION[L3].)
01-16A–1
Fuel tank side
atraaw00000592
1 Rollover valve 2 Charcoal canister

(See 01-16A-7 ROLLOVER VALVE REMOVAL/ (See 01-16A-3 CHARCOAL CANISTER REMOVAL/
(See 01-16A-8 ROLLOVER VALVE (See 01-16A-4 CHARCOAL CANISTER
INSPECTION[L3].) INSPECTION[L3].)
3 Check valve (Two-way)
End Of Sie
EMISSION SYSTEM DIAGRAM[L3]
id0116a2803600
PURGE SOLENOID
CATCH TANK VALVE
FUEL-FILLER CAP
CHARCOAL CANISTER
CHECK VALVE
AIR FILTER
EGR VALVE
ROLLOVER
VALVE
WU-TWC
PCV VALVE
TWC
atraaw00001129
End Of Sie
WM: CHARCOAL CANISTER
01-16A–2
CHARCOAL CANISTER REMOVAL/INSTALLATION[L3]
id0116a2803900
01
6.86—9.8 {70—99,
6.86—9.8 {70—99, 60—86}
60—86}
atraaw00000608
1 Charcoal canister protector 3 Charcoal canister

2 Air filter
End Of Sie
01-16A–3
CHARCOAL CANISTER INSPECTION[L3]
id0116a2800500
1. Remove the charcoal canister.
2. Plug the charcoal canister atmosphere side.
3. Using a vacuum pump, verify that vacuum is
maintained when vacuum is applied from the fuel
tank side.
• If there is an air leakage, replace the charcoal
canister. (See 01-16A-3 CHARCOAL
CANISTER REMOVAL/INSTALLATION[L3].)
End Of Sie
WM: PURGE SOLENOID VALVE
PLUG
atraaw00003077
PURGE SOLENOID VALVE REMOVAL/INSTALLATION[L3]

id0116a2804300
3. Install in the reverse order of removal. 7.8—10.8 {80—110 , 5 1
1 Connector 70—85}
2 Evaporative hose (To charcoal canister)

(See 01-16A-4 Evaporative Hose Installation Note.)
3 Vacuum hose (To intake manifold)
2
(See 01-16A-4 Vacuum Hose Installation Note.) 4 3
4 Purge solenoid valve
5 Bracket

atraaw00000637
Vacuum Hose Installation Note

1. Attach the vacuum hose onto the purge solenoid valve until it contacts the stopper.
Evaporative Hose Installation Note

1. Attach the evaporative hose onto the purge solenoid valve until it contacts the stopper.
End Of Sie
PURGE SOLENOID VALVE INSPECTION[L3]
id0116a2800900
Airflow inspection
2. Remove the purge solenoid valve. (See 01-16A-4 PURGE SOLENOID VALVE REMOVAL/INSTALLATION[L3].)
• If not as specified, replace the purge solenoid valve.
• If as specified, carry out the "Circuit Open/Short Inspection".
Terminal Port
Step B A
A B A B B A
1
2 B+ GND
atraaw00000601
atraaw00000600
01-16A–4
PURGE SOLENOID VALVE FUSE BOX
or short circuit (Continuity check). (MAIN RELAY)
WIRING HARNESS SIDE CONNECTOR
B A A E
FRONT
D 01
atraaw00000602
PCM
atraaw00000603
Open circuit
• If there is no continuity, there is an open circuit. Repair or replace the wiring harness.
— Purge solenoid valve terminal A and PCM terminal 2AN
— Purge solenoid valve terminal B and main relay terminal A
Short circuit
• If there is continuity, there is a short circuit. Repair or replace the wiring harness.
— Purge solenoid valve terminal A and power supply
— Purge solenoid valve terminal A and body ground
— Purge solenoid valve terminal B and body ground
End Of Sie
EGR VALVE REMOVAL/INSTALLATION[L3]
WM: EGR VALVE
id0116a2801000
3. Disconnect the EGR valve connector.
1 Water hose
(See 01-16A-5 Water Hose Removal Note.) R
2 EGR valve
(See 01-16A-6 EGR Valve Removal Note.)
3 Gasket
2
3 17—23 {1.8—2.3, 13—16}
1
atraaw00002991
Water Hose Removal Note

1. Drain the engine coolant from the radiator. (See 01-12A-4 ENGINE COOLANT REPLACEMENT[L3].)
01-16A–5
EGR Valve Removal Note
2. Remove the radiator hose (upper, engine side). (See 01-12A-7 RADIATOR REMOVAL/INSTALLATION[L3].)
End Of Sie
EGR VALVE INSPECTION[L3]
id0116a2801100
On-vehicle inspection
1. Verify that the buzzing sound (valve operation sound) is heard from the EGR valve when cranking the engine.
• If the buzzing sound is not heard, perform the “resistance inspection.”
Resistance inspection
2. Disconnect the EGR valve connector.
3. Measure the resistance between the EGR valve
terminals. C
• If within the specification, perform out the E
A
"Circuit Open/Short Inspection".
• If not within the specification, replace the
EGR valve. (See 01-16A-5 EGR VALVE F
B
REMOVAL/INSTALLATION[L3].) D
EGR valve terminal Resistance inspection

(ohm) EGR VALVE
CE
E
CA C
12—16 A
DB PCM MAIN RELAY
DF B
D
F
atraaw00000604

EGR VALVE FUSE BOX
or short circuit (Continuity check). WIRING HARNESS SIDE CONNECTOR (MAIN RELAY)
B
E C A
A E
F D B FRONT
D
atraaw00000605
PCM
atraaw00000606
01-16A–6
Open circuit
— EGR valve terminal A and PCM terminal 2AR
— EGR valve terminal B and PCM terminal 2AY
— EGR valve terminal C and main relay terminal A
— EGR valve terminal D and main relay terminal A
— EGR valve terminal E and PCM terminal 2AU
— EGR valve terminal F and PCM terminal 2AV
Short circuit
01
— EGR valve terminal A and power supply
— EGR valve terminal A and body ground
— EGR valve terminal B and power supply
— EGR valve terminal B and body ground
— EGR valve terminal C and body ground
— EGR valve terminal D and body ground
— EGR valve terminal E and power supply
— EGR valve terminal E and body ground
— EGR valve terminal F and power supply
— EGR valve terminal F and body ground
End Of Sie
POSITIVE CRANKCASE VENTILATION (PCV) VALVE INSPECTION[L3]
WM: PCV VALVE
id0116a2800400
1. Remove the PCV valve.
2. Verify that there is no airflow when pressurizing
port A (Intake manifold side). A
• If there is airflow, replace the PCV valve.
3. Verify that there is airflow when vacuum is applied
to port A.
• If there is no airflow, replace the PCV valve.
End Of Sie
WM: CATCH TANK
atraaw00002977
CATCH TANK INSPECTION[L3]

id0116a2804000
1. Remove the air cleaner cover. (See 01-13A-5 INTAKE-AIR SYSTEM REMOVAL/INSTALLATION[L3].)
2. Plug the catch tank of the purge solenoid valve
side.
3. Inspect for air leakage when blowing air using AIR CLEANER COVER
your mouth from charcoal canister.
• If there is air leakage, replace the air cleaner
cover.
End Of Sie
WM: ROLLOVER VALVE
PURGE SOLENOID
VALVE SIDE
CHARCOAL
CATCH
CANISTER SIDE
TANK
atraaw00003257
ROLLOVER VALVE REMOVAL/INSTALLATION[L3]

id0116a2804600
Note
• The rollover valve cannot be removed as it is built into the fuel tank.
End Of Sie
01-16A–7
ROLLOVER VALVE INSPECTION[L3]
id0116a2804500
Note
• The rollover valve cannot be disassembled and inspected as it is built into the fuel tank.
1. Perform the fuel tank inspection. (See 01-14A-9 FUEL TANK INSPECTION[L3].)
End Of Sie
01-16A–8
EMISSION SYSTEM [AJ (3.0L Duratec)]
01-16B EMISSION SYSTEM [AJ (3.0L Duratec)]

EMISSION SYSTEM LOCATION EGR VALVE INSPECTION
INDEX[AJ (3.0L Duratec)] . . . . . . . . . . 01-16B–1 [AJ (3.0L Duratec)] . . . . . . . . . . . . . . . . 01-16B–7
EMISSION SYSTEM DIAGRAM POSITIVE CRANKCASE
[AJ (3.0L Duratec)] . . . . . . . . . . . . . . . . 01-16B–3 VENTILATION (PCV) VALVE
CHARCOAL CANISTER INSPECTION[AJ (3.0L Duratec)] . . . . . 01-16B–9
REMOVAL/INSTALLATION EGR CONTROL VALVE
[AJ (3.0L Duratec)] . . . . . . . . . . . . . . . . 01-16B–4 REMOVAL/INSTALLATION 01
CHARCOAL CANISTER INSPECTION [AJ (3.0L Duratec)] . . . . . . . . . . . . . . . . 01-16B–8
[AJ (3.0L Duratec)] . . . . . . . . . . . . . . . . 01-16B–5 EGR CONTROL VALVE INSPECTION
PURGE SOLENOID VALVE [AJ (3.0L Duratec)] . . . . . . . . . . . . . . . . 01-16B–8
REMOVAL/INSTALLATION CATALYTIC CONVERTER
PURGE SOLENOID VALVE INSPECTION [AJ (3.0L Duratec)] . . . . . . . . . . . . . . . . 01-16B–9
[AJ (3.0L Duratec)] . . . . . . . . . . . . . . . . 01-16B–5 QUICK RELEASE CONNECTOR
EGR VALVE REMOVAL/INSTALLATION (EMISSION SYSTEM)
EGR PIPE REMOVAL/INSTALLATION [AJ (3.0L Duratec)] . . . . . . . . . . . . . . . . 01-16B–10
[AJ (3.0L Duratec)] . . . . . . . . . . . . . . . . 01-16B–7
End of Toc
EMISSION SYSTEM LOCATION INDEX[AJ (3.0L Duratec)]
WM: EMISSION SYSTEM
id0116a1803700
Engine Compartment Side
4
2
5
3
atraaw00003367
Purge solenoid valve EGR valve

(See 01-16B-5 PURGE SOLENOID VALVE (See 01-16B-6 EGR VALVE REMOVAL/
1 REMOVAL/INSTALLATION[AJ (3.0L Duratec)].) 2 INSTALLATION[AJ (3.0L Duratec)].)
(See 01-16B-5 PURGE SOLENOID VALVE (See 01-16B-7 EGR VALVE INSPECTION[AJ (3.0L
INSPECTION[AJ (3.0L Duratec)].) Duratec)].)
01-16B–1
PCV valve Quick release connector
(See 01-16B-9 POSITIVE CRANKCASE (See 01-16B-10 QUICK RELEASE CONNECTOR
3 5
VENTILATION (PCV) VALVE INSPECTION[AJ (EMISSION SYSTEM) REMOVAL/
(3.0L Duratec)].) INSTALLATION[AJ (3.0L Duratec)].)
EGR control valve
(See 01-16B-8 EGR CONTROL VALVE REMOVAL/
4 INSTALLATION[AJ (3.0L Duratec)].)
(See 01-16B-8 EGR CONTROL VALVE
Fuel Tank Side
atraaw00003368
Charcoal canister 2 Rollover valve

(See 01-16B-4 CHARCOAL CANISTER REMOVAL/ 3 Fuel filler cap
1 INSTALLATION[AJ (3.0L Duratec)].)
(See 01-16B-5 CHARCOAL CANISTER
End Of Sie
01-16B–2
EMISSION SYSTEM DIAGRAM[AJ (3.0L Duratec)]
id0116a1803600
EGR VALVE
EGR
PURGE
SOLENOID VALVE
CONTROL
VALVE
01
EGR PIPE
CANISTER
CHARCOAL
PCV VALVE
WU-TWC (RH)
:TO PCM
TWC
ROLLOVER VALVE
WU-TWC (LH)
atraaw00003291
End Of Sie
WM: CHARCOAL CANISTER
01-16B–3
CHARCOAL CANISTER REMOVAL/INSTALLATION[AJ (3.0L Duratec)]
id0116a1803900
Warning
• Highly flammable mixtures are always present and may be ignited, resulting in possible personal
injury. To prevent this, always keep all flames away when handling fuel system components.
• The evaporative emission system contains fuel vapor and condensed fuel vapor. Although not
present in large quantities, it still presents the danger of explosion or fire, causing possible
personal injury. To prevent this, disconnect the negative battery cable before performing work.

3. Disconnect the quick release connectors. (See
01-16B-10 QUICK RELEASE CONNECTOR
(EMISSION SYSTEM) REMOVAL/
atraaw00000566
4. Remove the nuts and the bolts, and remove the

charcoal canister and the bracket as a single unit.
atraaw00000568
5. Remove the charcoal canister bracket from the

charcoal canister.
Note
• Lubricate all O-ring seals with clean engine
oil.
Charcoal canister bracket installation bolt and

nut tightening torque
atraaw00000569
End Of Sie
01-16B–4
CHARCOAL CANISTER INSPECTION[AJ (3.0L Duratec)]
id0116a1800500
1. Remove the charcoal canister. (See 01-16B-4 CHARCOAL CANISTER REMOVAL/INSTALLATION[AJ (3.0L
Duratec)].)
2. Plug the charcoal canister atmosphere side.
3. Inspect for air leakage when applying air pressure
PLUG
from the fuel tank side.
• If there is an air leakage, replace the charcoal
canister.
End Of Sie FUEL TANK ATMOSPHERE 01
WM: PURGE SOLENOID VALVE
SIDE SIDE
aesffw00000409
PURGE SOLENOID VALVE REMOVAL/INSTALLATION[AJ (3.0L Duratec)]

id0116a1804300
Warning
• Highly flammable mixtures are always present and may be ignited, resulting in possible personal
injury. To prevent this, always keep all flames away when handling fuel system components.
• The evaporative emission system contains fuel vapor and condensed fuel vapor. Although not
present in large quantities, it still presents the danger of explosion or fire, causing possible
personal injury. To prevent this, disconnect the negative battery cable before performing work.

2. Disconnect the purge solenoid valve connectors
and quick release connectors. (See 01-16B-10
QUICK RELEASE CONNECTOR (EMISSION
SYSTEM) REMOVAL/INSTALLATION[AJ (3.0L
Duratec)].)
3. Disconnect the vacuum tube.
4. Disconnect the charcoal canister outlet tube.
5. Disconnect the evaporative emission (EVAP)
return tube.
atraaw00000941
6. Remove the two purge solenoid valve installation

nuts, and then remove the purge solenoid valve.
Purge solenoid valve installation nut

tightening torque
End Of Sie
PURGE SOLENOID
VALVE
atraaw00000942
PURGE SOLENOID VALVE INSPECTION[AJ (3.0L Duratec)]

id0116a1800900
2. Disconnect purge solenoid valve connectors.
3. Measure the resistance between purge solenoid valve terminals.
• If it is not within the specification, replace the purge solenoid valve.
• If the monitor item condition/specification (reference) is not within the specification, even though there is no
malfunction, perform the 'Circuit Open/Short Inspection'.
Purge solenoid valve resistance

30—38 ohms
01-16B–5
WIRING HARNESS-SIDE CONNECTOR MAIN FUSE BLOCK
(FUEL PUMP RELAY)
B
B A
A E
FRONT D
PCM
26 25 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
52 51 50 49 48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27
78 77 76 75 74 73 72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53
104103102 101100 99 98 97 96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79
atraaw00001256
Open circuit
— Purge solenoid valve terminal A and main relay terminal B
— Purge solenoid valve terminal B and PCM terminal 56
Short circuit
— Purge solenoid valve terminal A and body ground
— Purge solenoid valve terminal B and power supply
End Of Sie
EGR VALVE REMOVAL/INSTALLATION[AJ (3.0L Duratec)]
WM: EGR VALVE
id0116a1801000
2. Disconnect the vacuum hose.
3. Disconnect the EGR pipe. VACUUM HOSE
4. Remove the EGR valve. EGR VALVE
Caution
• Clean all sealing surfaces and install a
new EGR valve gasket.
EGR valve installation bolt tightening torque EGR PIPE

20—30 N·m {2.1—3.0 kgf·m, 15—22 ft·lbf}
atraaw00001004
EGR pipe tightening torque
35—45 N·m {3.6—4.5 kgf·m, 26—33 ft·lbf}
End Of Sie
WM: EGR SYSTEM
01-16B–6
EGR PIPE REMOVAL/INSTALLATION[AJ (3.0L Duratec)]
id0116a1803800
2. Remove the PCM wiring harness protector tightening bolt and position the PCM wiring harness protector out of
the way.
3. Remove the EGR pipe nut from the manifold
connector.
4. Remove the D.P.F. EGR sensor from the EGR
pipe. (See 01-40B-33 DIFFERENTIAL
PRESSURE FEEDBACK (D.P.F.) EGR SENSOR 01
atraaw00000121
5. Loosen the flare bolt and remove the EGR pipe.

Flare bolt tightening torque

35—45 N·m {3.6—4.5 kgf·m, 26—33 ft·lbf}
End Of Sie
WM: EGR VALVE
atraaw00001005
EGR VALVE INSPECTION[AJ (3.0L Duratec)]

id0116a1801100
Voltage Inspection
1. Connect the PDS/IDS.
2. Disconnect the vacuum hose from the EGR valve and plug the hose.
3. Install the vacuum pump to the EGR valve.
4. Start the engine and idle it.
5. Access the following PIDs using the PDS/IDS.
• DPFEGR (differential pressure feedback (D.P.F.) EGR sensor output voltage), RPM (engine speed)
6. Gradually apply vacuum to the EGR valve using the vacuum pump and verify that the DPFEGR PID value is as
indicated in the following table.
• If the DPFEGR PID is not as indicated in the following table, replace the EGR valve.
EGR valve characteristics standards

Vacuum applied to EGR valve DPFEGR PID value
Approx. 5.4 kPa Starts increasing (EGR valve starts opening)
Gradually apply vacuum Gradually increases
27—34 kPa 2.5 V or more
Keep applying 27—34 kPa for about 10 s Constant voltage (Voltage does not lower within several
seconds)
End Of Sie
WM: EGR SOLENOID VALVE
01-16B–7
EGR CONTROL VALVE REMOVAL/INSTALLATION[AJ (3.0L Duratec)]
id0116a1808000
2. Disconnect the EGR control valve connector.
3. Disconnect the vacuum hose. EGR CONTROL VALVE
VACUUM HOSE
atraaw00000957
4. Remove the EGR control valve.

5. Install in the reverse order of removal. EGR CONTROL VALVE
EGR control valve installation bolt tightening

torque
5—7 N·m {51—71 kgf·cm, 45—61 in·lbf}
End Of Sie
atraaw00000958
EGR CONTROL VALVE INSPECTION[AJ (3.0L Duratec)]

id0116a1808100
Airflow Inspection
1. Disconnect the vacuum hose from the EGR control valve (intake manifold side and EGR valve side).
2. Plug the EGR control valve port (EGR valve side).
3. Install the vacuum pump to the EGR control valve port (intake manifold side).
4. Verify that no vacuum is applied when applying vacuum to the EGR control valve using the vacuum pump.
• If vacuum remains, or it takes time to intake air, replace the EGR control valve.
2. Disconnect the EGR control valve connector.
3. Measure the resistance between the EGR control valve terminals.
• If it is not within the specification, replace the EGR control valve.
malfunction, perform the 'Circuit Open/Short Inspection'.
EGR control valve resistance

26—40 ohms
01-16B–8
EGR CONTROL VALVE
MAIN FUSE BLOCK
(FUEL PUMP RELAY)
B
B A A E 01
FRONT D
PCM
26 25 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
52 51 50 49 48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27
78 77 76 75 74 73 72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53
104103102 101100 99 98 97 96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79
atraaw00003256
Open circuit
— EGR control valve terminal A and main relay terminal B
— EGR control valve terminal B and PCM terminal 47
Short circuit
— EGR control valve terminal A and body ground
— EGR control valve terminal B and power supply
End Of Sie
POSITIVE CRANKCASE VENTILATION (PCV) VALVE INSPECTION[AJ (3.0L Duratec)]
WM: PCV VALVE
id0116a1800400
Note
• Removing the PCV valve might damage to
the tab of the PCV valve and it will not be
able to be reinstalled. Due to this, inspect
the PCV valve with it installed on the vehicle.
1. Disconnect the negative battery cable. PCV VALVE

2. Disconnect the PCV hose from the PCV valve. TAB
3. Apply pressure to the PCV valve and verify that
there is no airflow.
• If there is airflow, replace the PCV valve.
atraaw00000218
4. Apply vacuum to the PCV valve and verify that
there is airflow.
• If there is no airflow, replace the PCV valve.
End Of Sie
CATALYTIC CONVERTER REMOVAL/INSTALLATION[AJ (3.0L Duratec)]
WM: CATALYTIC CONVERTER
id0116a1804400
01-16B–9
2. Remove and discard the nuts.
3. Remove and discard the gasket.
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4. Remove the U-bolt and disconnect the catalytic

converter from the hanger, then remove the
catalytic converter.
U-bolt tightening torque

40.3—54.7 N·m {4.11—5.57 kgf·m, 29.8—40.3
ft·lbf}
40.3—54.7 N·m {4.11—5.57 kgf·m, 29.8—40.3
atraaw00000077
ft·lbf}
End Of Sie
QUICK RELEASE CONNECTOR (EMISSION SYSTEM) REMOVAL/INSTALLATION[AJ (3.0L Duratec)]
id0116a1805500
Quick Release Connector Type
Caution
• There are two types of quick release connector. Verify the type and location, and then remove/
install correctly.
TYPE B
TYPE A CHARCOAL CANISTER
TYPE A
atraaw00003372
01-16B–10
Type A
Removal
3. Depress the quick release connector release
tabs.
4. Remove the quick release connector. RELEASE TAB
01
atraaw00000944
Installation
Note
one.
atraaw00000945

atraaw00000946
Type B
Removal
3. Depress the quick release connector release
tabs.
4. Remove the quick release connector. RELEASE TAB
atraaw00001006
01-16B–11
Installation
Note
one.
atraaw00001007

End Of Sie
atraaw00001008
01-16B–12
CHARGING SYSTEM [L3]
01-17A CHARGING SYSTEM [L3]

CHARGING SYSTEM LOCATION INDEX GENERATOR REMOVAL/INSTALLATION
[L3] . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-17A–1 [L3] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-17A–4
BATTERY REMOVAL/INSTALLATION GENERATOR INSPECTION[L3] . . . . . . . 01-17A–6
[L3] . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-17A–2 GENERATOR DISASSEMBLY/ASSEMBLY
BATTERY INSPECTION[L3] . . . . . . . . . . 01-17A–2 [L3] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-17A–11
BATTERY RECHARGING[L3]. . . . . . . . . 01-17A–4
01
End of Toc
CHARGING SYSTEM LOCATION INDEX[L3]
WM: CHARGING SYSTEM
id0117a3800100
1
atraaw00000501
1 Battery 2 Generator
(See 01-17A-2 BATTERY REMOVAL/ (See 01-17A-4 GENERATOR REMOVAL/
(See 01-17A-2 BATTERY INSPECTION[L3].) (See 01-17A-6 GENERATOR INSPECTION[L3].)
(See 01-17A-4 BATTERY RECHARGING[L3].) (See 01-17A-11 GENERATOR DISASSEMBLY/
ASSEMBLY[L3].)
End Of Sie
WM: BATTERY
01-17A–1
BATTERY REMOVAL/INSTALLATION[L3]
id0117a3800500
.
1 Negative battery cable 2.0—6.9 {21—70, 18—61}

2 Positive battery cable 3
3 Battery clamp 4
2.9—4.9
4 Battery box {29.6—49.9,
(See 01-17A-2 Battery Box Installation Note.) 25.7—43.3}
5 Battery 2
6 Battery tray 2.9—4.9
1 {29.6—49.9,
25.7—43.3}
7.84—12.7
7.84—12.7
5 {80.0—129,
69.5—111}
{80.0—129,
69.5—111}
atraaw00002344
Battery Box Installation Note

1. Install the battery box so that the side with the
larger notch faces toward the front of vehicle.
End Of Sie
NOTCH
FRONT
atraaw00000517
BATTERY INSPECTION[L3]
id0117a3800600
Warning
• Since battery acid is toxic, be careful when handling the battery.
• Since battery acid is highly corrosive, be careful not to allow it to contact clothing or the vehicle.
• In case battery acid contacts skin, eyes, or clothing, flush it immediately with running water.
Especially if the acid gets in the eyes, flush with water for more than 15 min and get prompt
medical attention.
Electrolyte specific gravity

1. Measure the electrolyte specific gravity using a hydrometer.
• If it is less than the specification, recharge the battery. (See 01-17A-4 BATTERY RECHARGING[L3].)
Battery electrolyte specific gravity [20 °C {68 °F}]

1.22—1.29
01-17A–2
Battery voltage
1. Inspect the battery as follows:
Step Inspection Action
1 Measure the battery 12.4 V or Go to Step
positive voltage. more 3.
Less Go to the
than next step.
12.4 V
2 Quick charge for 30 12.4 V or Go to the 01
min and recheck more next step.
voltage. Less Replace the
than battery.
12.4 V
3 Using the battery load Yes Normal
tester, apply load No Replace the
current (see battery battery.
load test current) and
record battery voltage
after 15 s. Is voltage
more than the
specification?
Battery load test current

55D23L (48): 180 A
Standard specification
Battery temp. (°C {°F}) Minimum voltage (V)
4 {39} 9.3
10 {50} 9.4
16 {61} 9.5
21 {70} 9.6
Back-up current
1. Verify that the ignition switch is off (key has been removed) and that all doors are closed.
3. Connect the tester between the negative battery terminal and negative battery cable, leave the battery
undisturbed for 30 min, and then measure the back-up current.
• If not within the specification, measure the back-up current while removing the fuses one by one from the
inside of the main fuse block and the inside of the fuse block.
Note
• If the battery is not left undisturbed for 30 min, the tester will indicate a high value (approx. 300 mA).
• If the key or any electrical accessory is operated within approx. 30 min after the tester is connected, the
battery must be left undisturbed for approx. 30 min from that point.
Caution
• Operating electrical loads while the back-up current is being measured can damage the tester.
Note
• For vehicles with the immobilizer system, the system periodically shifts synchronization of the security
light flashing. Therefore, 45 mA (0.1 s) current is supplied when the security light is illuminated, and 25
mA (2 s) current is supplied when the security light is not illuminated. In addition, the measuring
instrument, which shows the average value, indicates around 30 mA.
Battery back-up current

Vehicles with immobilizer system: 25—45 mA
Vehicles without immobilizer system: 30 mA or less
4. Inspect and repair wiring harnesses and connectors of the fuse where the current has decreased.
End Of Sie
01-17A–3
BATTERY RECHARGING[L3]
id0117a3800700
Warning
• Keep all flames away from the battery, otherwise evaporated gas from the battery fluid may catch
fire, and cause serious injury.
• Remove the battery filler caps when recharging to prevent battery deformation or damage (if
equipped).
Caution
• Do not quick charge for more than 30 min. It will damage the battery.
1. Remove the battery filler caps (if equipped).

2. Remove the battery and then place it in a pan of
water.
3. Connect a battery charger to the battery and
adjust the charging current as follows.
BATTERY BATTERY
CHARGER
Battery slow charge current
55D23L (48): Approx. 4.8 A (10 h)
4. After the battery is recharged, verify that the

voltage is within the specification and remains at
the same value for 1 h or more after the
recharging has been completed.
atraaw00000518
battery.
Standard voltage
12.4 V or more
End Of Sie
GENERATOR REMOVAL/INSTALLATION[L3]
WM: GENERATOR
id0117a3800200
Warning
serious injury.
• When the battery cables are connected, touching the vehicle body with generator terminal B will
generate sparks. This can cause personal injury, fire, and damage to the electrical components.
Always disconnect the negative battery cable before performing the following operation.
Caution
• The generator can be damaged by the heat from the exhaust manifold. Make sure the generator
duct and the generator heat insulator are installed securely.

4. Position the P/S pressure hose out of the way.
5. Remove the exhaust manifold insulator. (See 01-15A-2 EXHAUST SYSTEM REMOVAL/INSTALLATION[L3].)
01-17A–4
9.8—14.7 N·m
{100—149 kgf·cm,
87—130 in·lbf}
2.9—4.9 N·m
{30—50 kgf·cm,
26—43 in·lbf}
3
5
01
7.8—10.8 N·m 4
{79.6—110.1 kgf·cm,
69.1—95.5 in·lbf}
2
7.8—10.8 N·m
{79.6—110.1 kgf·cm, 38—51 B
69.1—95.5 in·lbf} {3.9—5.2,
29—37} C
38—51 {3.9—5.2, 29—37}
1 N·m {kgf·m, ft·lbf}
atraaw00000502
1 Generator duct 5 Generator and generator heat insulator

2 Wiring harness bracket (See 01-17A-5 Generator and Generator Heat
Insulator Removal Note.)
3 Terminal B cable (See 01-17A-5 Generator and Generator Heat
4 Generator connector Insulator Installation Note.)
Generator and Generator Heat Insulator Removal Note

1. Remove the generator and generator heat insulator together from the engine, and position them in the engine
compartment in a location where no part can be damaged.
2. Remove the generator heat insulator from the generator.
3. Remove the generator from above the engine compartment.
Generator and Generator Heat Insulator Installation Note

1. From above the engine compartment, set the generator down inside the engine compartment in a position
where no part can be damaged.
2. Install the generator heat insulator to the generator.
3. Install the generator and generator heat insulator together to the engine.
4. Tighten bolt A temporarily.
5. Tighten bolt B, C to the specified tightening torque.
6. Tighten bolt A to the specified tightening torque.
End Of Sie
01-17A–5
GENERATOR INSPECTION[L3]
id0117a3800300
Caution
• Do not apply direct battery positive voltage to generator terminal D, otherwise it could cause
damage to the internal parts (power transistor) of the generator.
Generator Warning Light

2. Verify that the drive belt deflection/tension is correct. (See 01-10A-3 DRIVE BELT INSPECTION[L3].)
3. With the ignition switch turned to the ON position, verify that the generator warning light illuminates.
• If it does not illuminate, inspect the generator warning light and the wiring harness.
— If the generator warning light and the wiring harness are normal, inspect the PCM.
4. Verify that the generator warning light goes out after the engine is started.
• If it does not go out, inspect if any one of the following DTCs in the on-board diagnostic system are
displayed: P0112, P0113, P2502, P2503, P2504. (See 01-02A-13 DTC TABLE[L3].)
Generator
Voltage
3. Turn off all electrical loads.
5. Verify that the generator rotates smoothly without any noise while the engine is running.
• If there is any noise, find the cause and repair or replace the generator.
6. Measure the voltage at each terminal using a
tester.
• If it is not as specified, find the cause and
repair or replace the applicable part.
D P
Generator standard voltage [IG-ON]
Terminal B: B+
Terminal P: Approx. 1 V or less
Terminal D: Approx. 0 V
Generator standard voltage [Idle, 20 °C {68

°F}]
atraaw00000503
Terminal B: 13—15 V
Terminal P: Approx. 3—8 V
Terminal D: Turn the electrical loads (headlights, blower motor, rear window defroster) on and verify
that the voltage reading increases.
Current
Note
• Since the charging current decreases rapidly after starting the engine, carry out the following procedure
quickly, and read the maximum current value.

4. Connect a tester, which can read 120 A or more, between generator terminal B and the wiring harness.
8. Increase engine speed to 2,500 rpm.
Note
• When the electrical load on the vehicle is low, the specified current cannot be verified although the
generator is normal. In this case, increase the electrical load (Leave the headlights turned on for a while,
then discharge the battery, or use a similar method.) and recheck.
• When the generator itself or the ambient temperature are too high, the specified current also cannot be
verified. In this case, cool down the generator and recheck.
01-17A–6
9. Turn the following electrical loads on and verify that the current reading increases more than the minimum
value indicated below.
— If it is not as specified, go to the PCM and generator shearing inspection. (See 01-17A-7 PCM and
generator shearing inspection.)
• Headlights (high-beam)
• Blower motor (HI)
• Rear window defroster
• Brake lights
Generator generated current minimum value

01
70 % of the nominal output current (nominal output current: 110 A)
[Ambient temp. 20 °C {68 °F}, voltage 13.0—15.0 V, both engine and generator are hot]
PCM and generator shearing inspection

2. Inspect as follows:
DLC-2
aesffw00000158

1 Measure the generator terminal B voltage when the 15 V or more Go to Step 2.
electrical loads*1 are on and off. 13—15 V Normal*2
13 V or less Go to Step 3.
2 Monitor the ALTT V PID using the PDS/IDS, or measure Yes Go to Step 4.
the voltage of PCM terminal 2AM using a tester. Is the No PCM input error.
voltage between 13 and 15 V ?
3 Monitor the ALTT V PID using the PDS/IDS, or measure Yes Go to Step 5.
the voltage of PCM terminal 2AM using a tester. Is the No PCM input error.
voltage between 13 and 15 V ?
4 Monitor the ALTF PID using the PDS/IDS, or calculate the Yes PCM input error.
duty value of the PCM terminal 2AQ using an oscilloscope. No PCM, generator, or
Is the duty value 100 % ? both are not
normal.
A
0V
A
x 100 (%) = DUTY (%)
B
01-17A–7
5 Monitor the ALTF PID using the PDS/IDS, or calculate the Yes PCM input error.
duty value of the PCM terminal 2AQ using an oscilloscope. No PCM, generator, or
Is the duty value 0 % ? both are not
normal.
A
0V
A
x 100 (%) = DUTY (%)
B
*1 : Headlights, blower motor, rear window defroster, and brake lights.

*2
: If the generator field coil duty value does not change when electrical loads (such as headlights, blower motor,
rear window defroster, brake lights) are on or off, inspection with discharged battery is needed.
Generator Inner Parts

Rotor
1. Measure the resistance between the slip rings
using a tester.
rotor.
Generator rotor resistance (between slip

rings) [20 °C {68 °F}]
1.8—2.2 ohm
atraaw00000506
2. Verify that there is no continuity between the slip

ring and core using a tester.
• If there is continuity, replace the rotor.
3. Inspect the slip ring surface condition.
• If the slip ring surface is rough, use a lathe or
fine sandpaper to smooth it.
atraaw00000507
Stator coil
1. Verify that the continuity is as indicated in the table.
: Continuity
Terminal
1 6
1 2 3 4 5 6
2 5
3 4
atraaw00000509 atraaw00000508
• If there is any malfunction, replace the stator.
01-17A–8
2. Verify that there is no continuity between the
stator coil leads and core using a tester.
• If there is continuity, replace the stator coil.
01
atraaw00000510
Brush
1. Inspect brushes for wear.
• If any brush is worn almost to or beyond the
limit, replace all of the brushes.
MINIMUM
Generator brush length
Standard: 22.5 mm {0.89 in}
Minimum: 5.0 mm {0.20 in}
STANDARD
atraaw00000511
Brush spring
1. Measure the force of the brush spring using a spring pressure gauge.
2. Read the spring pressure gauge at the brush tip
projection of 2 mm {0.079 in}.
• Replace the brush spring if necessary.
Generator brush spring force

Standard: 4.1—5.3 N {0.42—0.54 kgf, 0.92— 2 mm
{0.079 in}
1.19 lbf}
Minimum: 1.7 N {0.17 kgf, 0.38 lbf}
atraaw00000512
Rectifier (Using an analog circuit tester)

1. Inspect for continuity of the diodes using an
analog circuit tester. P4 P5
P6
• If not as specified, replace the rectifier.
Specification P3
Negative Positive Continuity
P2
E P1, P2, P3, P4, Yes
B P5, P6 No P1
P1, P2, P3, P4, E No
P5, P6 B Yes
E B
atraaw00000513
01-17A–9
Rectifier (Using a digital circuit tester)
1. Inspect for continuity of the diodes using a digital circuit tester.
• If not as specified, replace the rectifier.
Specification
Negative Positive Continuity
E P1, P2, P3, P4, No
B P5, P6 Yes
P1, P2, P3, P4, E Yes
P5, P6 B No
Bearing
1. Inspect for abnormal noise, looseness, and
sticking.
• Replace the bearing if necessary.
End Of Sie
atraaw00000514
01-17A–10
GENERATOR DISASSEMBLY/ASSEMBLY[L3]
id0117a3800400
Caution
• Melt the solder quickly, otherwise the diodes (rectifier) and regulator will be damaged by excessive
heat.
1. Disassemble in the order indicated in the table.

01
4
1
2
3.5—5.3 6
{35—55, 31—47}
6.9—10.8
11 {70—110, 61—96}
9
5
2.9—4.9
{30—50,
26—43}
98—137 N·m
3
{10.0—13.9 kgf·m, 7
2.9—4.9
72—101 ft·lbf} 2.9—4.9
{30—50,
{30—50,
26—43}
26—43}
10
1.5—2.5 2.9—4.9
{15—25, 13—22} {30—50,
26—43}
8
1.5—2.5
{15—25, 13—22}

acxuuw00002030
1 Rotor component 7 Generator heat insulator

2 Stator coil component 8 Stator coil
3 Pulley 9 Rectifier
4 Rotor 10 Brush holder
5 Bearing 11 Rear bracket
6 Front cover
End Of Sie
01-17A–11
CHARGING SYSTEM [AJ (3.0L Duratec)]
01-17B CHARGING SYSTEM [AJ (3.0L Duratec)]

CHARGING SYSTEM LOCATION INDEX BATTERY RECHARGING
BATTERY REMOVAL/INSTALLATION GENERATOR REMOVAL/INSTALLATION
BATTERY INSPECTION GENERATOR INSPECTION
01
End of Toc
CHARGING SYSTEM LOCATION INDEX[AJ (3.0L Duratec)]
WM: CHARGING SYSTEM
id0117a1800100
1
atraaw00001540
1 Battery 2 Generator
(See 01-17B-2 BATTERY REMOVAL/ (See 01-17B-4 GENERATOR REMOVAL/
(See 01-17B-2 BATTERY INSPECTION[AJ (3.0L (See 01-17B-5 GENERATOR INSPECTION[AJ
Duratec)].) (3.0L Duratec)].)
(See 01-17B-4 BATTERY RECHARGING[AJ (3.0L
Duratec)].)
End Of Sie
WM: BATTERY
01-17B–1
BATTERY REMOVAL/INSTALLATION[AJ (3.0L Duratec)]
id0117a1800500
.
1 Negative battery cable 2.0—6.9 {21—70, 18—61}

2 Positive battery cable 3
3 Battery clamp
2.9—4.9
4 Battery {29.6—49.9,
25.7—43.3}
5 Battery tray
2
End Of Sie
2.9—4.9
1 {29.6—49.9,
25.7—43.3}
7.84—12.7
7.84—12.7 4 {80.0—129,
69.5—111}
{80.0—129,
69.5—111}
atraaw00002343
BATTERY INSPECTION[AJ (3.0L Duratec)]

id0117a1800600
Warning
• Since battery acid is toxic, be careful when handling the battery.
• Since battery acid is highly corrosive, be careful not to allow it to contact clothing or the vehicle.
• In case battery acid contacts skin, eyes, or clothing, flush it immediately with running water.
Especially if the acid gets in the eyes, flush with water for more than 15 min and get prompt
medical attention.
Electrolyte specific gravity

1. Measure the electrolyte specific gravity using a hydrometer.
• If it is less than the specification, recharge the battery. (See 01-17B-4 BATTERY RECHARGING[AJ (3.0L
Duratec)].)
Battery electrolyte specific gravity [20 °C {68 °F}]

1.22—1.29
Battery voltage
1. Inspect the battery as follows:
1 Measure the battery 12.4 V or Go to Step
positive voltage. more 3.
Less Go to the
than next step.
12.4 V
2 Quick charge for 30 12.4 V or Go to the
min and recheck more next step.
voltage. Less Replace the
than battery.
12.4 V
01-17B–2
3 Using the battery load Yes Normal
tester, apply load No Replace the
current (see battery battery.
load test current) and
record battery voltage
after 15 s. Is voltage
more than the
specification?
01
Battery load test current
80D26L (55): 195 A
Standard specification
Battery temp. (°C {°F}) Minimum voltage (V)
4 {39} 9.3
10 {50} 9.4
16 {61} 9.5
21 {70} 9.6
Back-up current
1. Verify that the ignition switch is off (key has been removed) and that all doors are closed.
3. Connect the tester between the negative battery terminal and negative battery cable, leave the battery
undisturbed for 30 min, and then measure the back-up current.
• If not within the specification, measure the back-up current while removing the fuses one by one from the
inside of the main fuse block and the inside of the fuse block.
Note
• If the battery is not left undisturbed for 30 min, the tester will indicate a high value (approx. 300 mA).
• If the key or any electrical accessory is operated within approx. 30 min after the tester is connected, the
battery must be left undisturbed for approx. 30 min from that point.
Caution
• Operating electrical loads while the back-up current is being measured can damage the tester.
Note
• For vehicles with the immobilizer system, the system periodically shifts synchronization of the security
light flashing. Therefore, 45 mA (0.1 s) current is supplied when the security light is illuminated, and 25
mA (2 s) current is supplied when the security light is not illuminated. In addition, the measuring
instrument, which shows the average value, indicates around 30 mA.

4. Inspect and repair wiring harnesses and connectors of the fuse where the current has decreased.
End Of Sie
01-17B–3
BATTERY RECHARGING[AJ (3.0L Duratec)]
id0117a1800700
Warning
• Keep all flames away from the battery, otherwise evaporated gas from the battery fluid may catch
fire, and cause serious injury.
• Remove the battery filler caps when recharging to prevent battery deformation or damage (if
equipped).
1. Remove the battery filler caps (if equipped).

2. Remove the battery and then place it in a pan of
water.
3. Connect a battery charger to the battery and
adjust the charging current as follows.
BATTERY BATTERY
CHARGER
Battery slow charge current
80D26L (55): Approx. 5.5 A (10 h)
4. After the battery is recharged, verify that the

voltage is within the specification and remains at
the same value for 1 h or more after the
recharging has been completed.
atraaw00000499
battery.
Standard voltage
12.4 V or more
End Of Sie
GENERATOR REMOVAL/INSTALLATION[AJ (3.0L Duratec)]
WM: GENERATOR
id0117a1800200
Warning
serious injury.
• When the battery cables are connected, touching the vehicle body with generator terminal B will

3. Remove the transverse member. (See 02-13-9 FRONT CROSSMEMBER REMOVAL/INSTALLATION.)
4. Remove the front pipe. (See 01-15B-4 FRONT PIPE REMOVAL/INSTALLATION[AJ (3.0L Duratec)].)
5. Remove the drive shaft (RH). (See 03-13-7 FRONT DRIVE SHAFT REMOVAL/INSTALLATION.)
6. Remove the drive belt from the generator. (See 01-10B-4 DRIVE BELT REMOVAL/INSTALLATION[AJ (3.0L
Duratec)].)
7. Remove the upper generator mounting bolt.
40—50 N·m {4.1—5.0 kgf·m, 30—36 ft·lbf}
atraaw00000493
01-17B–4
8. Remove the lower generator bolts and move the
generator to the side. 40—50 N·m {4.1—5.0 kgf·m, 30—36 ft·lbf}
01
atraaw00000494
9. Remove the generator mounting bracket bolts,

then remove the bracket. 20 N·m {2.0 kgf·m, 14 ft·lbf}
atraaw00000495
10. Remove the generator connector.

(1) Remove the terminal B installation nut and the 2
cable.
(2) Remove the connector.
11. Rotate the generator to open a space, then
remove the generator through the fender well
opening.
12. Install in the reverse order of removal. 1
End Of Sie
7.2—10.8 N·m {73.5—110 kgf·cm,
63.8—95.4 in·lbf}
atraaw00001584
GENERATOR INSPECTION[AJ (3.0L Duratec)]

id0117a1800300
Generator Warning Light
2. Verify that the drive belt deflection/tension is correct. (See 01-10B-3 DRIVE BELT INSPECTION[AJ (3.0L
Duratec)].)
3. With the ignition switch turned to the ON position, verify that the generator warning light illuminates.
• If it does not illuminate, inspect the generator warning light and the wiring harness between the battery,
generator warning light, and PCM.
• If the generator warning light and the wiring harness are normal, inspect the PCM.
4. Verify that the generator warning light goes out after the engine is started.
• If it does not goes out, inspect the generator.
Generator
Voltage
Duratec)].)
5. Verify that the generator rotates smoothly without any noise while the engine is running.
• If there is any noise, find the cause and repair or replace the generator.
01-17B–5
6. Measure the voltage at each terminal using a
tester.
• If it is not as specified, find the cause and
repair or replace the applicable part.
S L
Generator standard voltage [IG-ON]
Terminal B: B+
Terminal L: Approx. 1 V or less
Terminal S: B+
Generator standard voltage [Idle, 20 °C {68

°F}]
atraaw00000497
Terminal L: 13—15 V
Terminal S: 13—15 V
Current
Note
• Since the charging current decreases rapidly after starting the engine, carry out the following procedure
quickly, and read the maximum current value.

Duratec)].)
4. Connect a tester, which can read 120 A or more, between generator terminal B and the wiring harness.
8. Increase engine speed to 2,000 rpm.
Note
• When the electrical load on the vehicle is low, the specified current cannot be verified although the
generator is normal. In this case, increase the electrical load (Leave the headlights turned on for a while,
then discharge the battery, or use a similar method.) and recheck.
• When the generator itself or the ambient temperature are too high, the specified current also cannot be
verified. In this case, cool down the generator and recheck.
9. Turn the following electrical loads on and verify that the current reading increases more than the minimum
value indicated below.
• Headlights (high-beam)
• Blower motor (HI)
• Rear window defroster
• Brake lights

58 A [Generator terminal B voltage: 13.0—15.0 V, engine speed: 2,000 rpm]
End Of Sie
01-17B–6
IGNITION SYSTEM [L3]
01-18A IGNITION SYSTEM [L3]

IGNITION SYSTEM LOCATION INDEX IGNITION COIL INSPECTION[L3] . . . . . . 01-18A–2
[L3] . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-18A–1 SPARK PLUG
IGNITION COIL REMOVAL/INSTALLATION[L3] . . . . . . . 01-18A–3
REMOVAL/INSTALLATION[L3] . . . . . . 01-18A–2 SPARK PLUG INSPECTION[L3] . . . . . . . 01-18A–3
End of Toc
IGNITION SYSTEM LOCATION INDEX[L3]
WM: IGNITION SYSTEM
01
id0118a2800100
atraaw00000526
1 Ignition coil 2 Spark plug

(See 01-18A-2 IGNITION COIL REMOVAL/ (See 01-18A-3 SPARK PLUG REMOVAL/
(See 01-18A-2 IGNITION COIL INSPECTION[L3].) (See 01-18A-3 SPARK PLUG INSPECTION[L3].)
End Of Sie
WM: IGNITION COIL
01-18A–1
IGNITION COIL REMOVAL/INSTALLATION[L3]
id0118a2800200
1 Connector 6.0—9.5
{62—96,
2 Ignition coil 54—83}
End Of Sie
1
atraaw00000527
IGNITION COIL INSPECTION[L3]

id0118a2800300
Ignition Coil Inspection
1. Perform the spark test and identify the malfunctioning cylinder.
2. Replace the ignition coil of the malfunctioning cylinder with that of a normal cylinder, and reperform the spark
test.
• If the spark is not normal due to a malfunctioning ignition coil, replace that ignition coil.
• It is unlikely that all four ignition coils fail to operate properly. To prevent replacing a normal component,
perform the above procedure, identify the malfunctioning ignition coil, and replace it.
Ignition Coil with Built-in Igniter Inspection

01-18A–2
3. Measure the resistance between each terminal on the ignition coil connector using an analog circuit tester.
• If the measurement corresponds to the table, replace the ignition coil.
Tester Connection Position
Item Condition
Positive Negative
A C
0 ohm is not normal (∞ ohm is normal)
Terminal B C
A B ∞ or 0 ohm is not normal (several kilohm is normal)
End Of Sie
01
WM: SPARK PLUG
A B C
atraaw00000528
SPARK PLUG REMOVAL/INSTALLATION[L3]

id0118a2800400
Caution
• If a spark plug that is not as specified is installed, engine performance will be deteriorated. Install
only the specified spark plug when replacing.

3. Remove the spark plugs using a plug-wrench.
Tightening torque
10—14 N·m {1.1—1.4 kgf·m, 8—10 ft·lbf}
End Of Sie
SPARK PLUG INSPECTION[L3]
id0118a2800500
Specification
Spark plug type

LFG1 18 110 (ILTR5A-13G), L3Y2 18 110
Plug Gap Inspection
Caution
• To avoid possible damage to the tip, do not adjust the plug gap.
• To prevent damaging the tip, use a wire type plug gap gauge when inspecting the plug gap.
1. Measure the spark plug gap using a wire type plug gap gauge.
• If not within the specification, replace the spark plug.
Spark plug gap

1.25—1.35 mm {0.050—0.053 in}
01-18A–3
Cleaning
Caution
• Carbon may adhere to the tip of the spark plug during vehicle delivery or repeated short distance
driving during the winter time. If there is any malfunction such as rough idling or start difficulty
due to carbon adhesion causing plug fouling, burn off the carbon by performing no-load racing of
the engine.
• When performing the no-load racing, apply the side brake and foot brake, move the selector lever
to P position to prevent an accident and serious injury.
• To avoid possible damage to the spark plug tip, do not use a wire brush for cleaning.
Note
• To avoid possible damage to the tip, use gasoline to clean the spark plugs after removing dirt.
• If the accelerator pedal is depressed continuously for a specified time, the engine speed may decrease to
the idle speed. This is due to the fuel cut control operation, which prevents overheating, and it does not
indicate a malfunction.
• Do not perform no-load racing at high engine speed continuously for 10 s or more.
1. If there is carbon adhering to the spark plug, perform no-load racing.
Visual Inspection
• If any of the following malfunctions are DAMAGE BREAKAGE
indicated, replace the spark plug. BURNS
— Insulator breakage
— Worn electrode
— Damaged gasket
— Badly burned insulator (sparking side) WEAR AND
CARBON
DEPOSITS
atraaw00000529
1. Measure the resistance of the spark plug using a
tester as shown in the figure.
spark plug.
Spark plug resistance [25 °C {77 °F}]

3.0—7.5 kilohms
End Of Sie
atraaw00000530
01-18A–4
IGNITION SYSTEM [AJ (3.0L Duratec)]
01-18B IGNITION SYSTEM [AJ (3.0L Duratec)]

IGNITION SYSTEM LOCATION INDEX SPARK PLUG REMOVAL/INSTALLATION
IGNITION COIL REMOVAL/INSTALLATION SPARK PLUG INSPECTION
IGNITION COIL INSPECTION
[AJ (3.0L Duratec)] . . . . . . . . . . . . . . . . 01-18B–2
01
End of Toc
IGNITION SYSTEM LOCATION INDEX[AJ (3.0L Duratec)]
WM: IGNITION SYSTEM
id0118a1800100
atraaw00000519
1 Ignition coil 2 Spark plug

(See 01-18B-2 IGNITION COIL REMOVAL/ (See 01-18B-3 SPARK PLUG REMOVAL/
(See 01-18B-2 IGNITION COIL INSPECTION[AJ (See 01-18B-3 SPARK PLUG INSPECTION[AJ
(3.0L Duratec)].) (3.0L Duratec)].)
End Of Sie
WM: IGNITION COIL
01-18B–1
IGNITION COIL REMOVAL/INSTALLATION[AJ (3.0L Duratec)]
id0118a1800200
Duratec)].)
Caution
• Apply small amount of the specified dielectric grease to the inside of the ignition coils, then install
the ignition coils to the spark plugs.
— Specified grease: Motorcraft XG-3A
5. Install in the reverse order of removal..

6.0—8.0 {62—81, 54—70}
1 Connector
2 Ignition coil
1
End Of Sie
2
SEALANT

atraaw00000520
IGNITION COIL INSPECTION[AJ (3.0L Duratec)]

id0118a1800300
Primary Coil Resistance
2. Using a tester, measure the resistance between
the ignition coil terminals A—B.
ignition coil.
B A
Ignition coil primary coil resistance
(reference) [25 °C {77 °F}]
0.45—1.15 ohms
atraaw00000521
Secondary Coil Resistance

1. Remove the ignition coils. (See 01-18B-2 IGNITION COIL REMOVAL/INSTALLATION[AJ (3.0L Duratec)].)
the ignition coil terminal A and ignition coil boot
socket. A
ignition coil.
Ignition coil secondary coil resistance

(reference) [25 °C {77 °F}]
5.0—6.0 kilohms
atraaw00000522
01-18B–2
Insulation Resistance of Case
the ignition coil terminal A and the ignition coil
case. A
• If not as specified, replace the ignition coil.
Ignition coil insulation resistance of case

(reference) [25 °C {77 °F}] 01
10 Megohms
End Of Sie
WM: SPARK PLUG
atraaw00000523
SPARK PLUG REMOVAL/INSTALLATION[AJ (3.0L Duratec)]

id0118a1800400
Caution
• If a spark plug that is not as specified is installed, engine performance will be deteriorated. Install
only the specified spark plug when replacing.

Duratec)].)
4. Remove the ignition coils. (See 01-18B-2 IGNITION COIL REMOVAL/INSTALLATION[AJ (3.0L Duratec)].)
5. Remove the spark plugs using a plug-wrench.
Caution
• Apply small amount of the specified dielectric grease to the inside of the ignition coils, then install
the ignition coils to the spark plugs.
— Specified grease: Motorcraft XG-3A
Tightening torque
9—20 N·m {91—204 kgf·cm, 79—177 in·lbf}
End Of Sie
SPARK PLUG INSPECTION[AJ (3.0L Duratec)]
id0118a1800500
Specification
Spark plug type

AJ11 18 110 (AGSF-32N)
Spark Plug Gap Inspection/Adjustment

1. Inspect the spark plug gap.
• If not within the specification, adjust the spark plug gap.
Spark plug gap

1.32—1.42 mm {0.052—0.055 in}
Cleaning
1. If there is carbon adhering to the spark plug, clean it with a wire brush and remove the carbon.
Note
• If there is no spark plug cleaner when cleaning the spark plug, remove the dirt from the spark plug
completely and wash with gasoline.
01-18B–3
Visual Inspection
• If any of the following malfunctions are DAMAGE BREAKAGE
indicated, replace the spark plug. BURNS
— Insulator breakage
— Worn electrode
— Damaged gasket
— Badly burned insulator (sparking side) WEAR AND
CARBON
DEPOSITS
atraaw00000524
1. Measure the resistance of the spark plug using a
tester as shown in the figure.
spark plug.
Spark plug resistance [25 °C {77 °F}]

2.0—20.0 kilohms
End Of Sie
atraaw00000525
01-18B–4
STARTING SYSTEM [L3]
01-19A STARTING SYSTEM [L3]

STARTING SYSTEM LOCATION INDEX STARTER INSPECTION[L3] . . . . . . . . . . 01-19A–3
[L3] . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-19A–1
STARTER REMOVAL/INSTALLATION
[L3] . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-19A–2
End of Toc
STARTING SYSTEM LOCATION INDEX[L3]
WM: STARTING SYSTEM
01
id0119a2800100
atraaw00000535
1 Starter
(See 01-19A-2 STARTER REMOVAL/
INSTALLATION[L3].)
(See 01-19A-3 STARTER INSPECTION[L3].)
End Of Sie
WM: STARTER
01-19A–1
STARTER REMOVAL/INSTALLATION[L3]
id0119a2800200
Warning
serious injury.
• When the battery cables are connected, touching the vehicle body with starter terminal B will

2. Position the both splash shields out of the way.
9.8—11.7 N·m 2
{100—119 kgf·cm,
86.8—103.5 in·lbf}
3 38—51 {3.9—5.2, 29—37}
16.3—23.5
{1.7—2.3,
12.1—17.3}
FRONT
38—51 {3.9—5.2, 29—37}
atraaw00000536
1 Water hose bracket 3 Terminal S connector

2 Terminal B cable 4 Starter
End Of Sie
01-19A–2
STARTER INSPECTION[L3]
id0119a2800300
On-vehicle Inspection
2. The starter is normal if it rotates smoothly and without any noise when the engine is cranked.
• If the starter does not operate, inspect the following:
— Remove the starter, and inspect the starter unit.
— Inspect the related wiring harnesses, the ignition switch, and the transaxle range switch.
No-load Test 01
2. Connect the starter, battery, and a tester as
IG SW TESTER
3. Operate the starter and verify that it rotates
A
smoothly.
• If the starter does not rotate smoothly, inspect B
the starter unit. M TESTER

4. Measure the voltage and current while the starter S TERMINAL V BATTERY
is operating. STARTER
starter.
Starter no-load test voltage

atraaw00000537
11 V
Starter no-load test current

90 A or less
End Of Sie
01-19A–3
STARTING SYSTEM [AJ (3.0L Duratec)]
01-19B STARTING SYSTEM [AJ (3.0L Duratec)]

STARTING SYSTEM LOCATION INDEX STARTER INSPECTION
STARTER REMOVAL/INSTALLATION
[AJ (3.0L Duratec)] . . . . . . . . . . . . . . . . 01-19B–2
End of Toc
STARTING SYSTEM LOCATION INDEX[AJ (3.0L Duratec)]
WM: STARTING SYSTEM
01
id0119a1800100
atraaw00000531
1 Starter
(See 01-19B-2 STARTER REMOVAL/
(See 01-19B-2 STARTER INSPECTION[AJ (3.0L
Duratec)].)
End Of Sie
WM: STARTER
01-19B–1
STARTING SYSTEM [AJ (3.0L Duratec)]
STARTER REMOVAL/INSTALLATION[AJ (3.0L Duratec)]
id0119a1800200
Warning
serious injury.
• When the battery cables are connected, touching the vehicle body with starter terminal B will
1. Remove the battery. (See 01-17B-2 BATTERY REMOVAL/INSTALLATION[AJ (3.0L Duratec)].)

3. Position the selector cable and selector cable bracket component out of the way.
5. Install in the reverse order of removal..
37.3—52 {3.8—5.3, 27.5—38.3}
1 Terminal B cable
2 Terminal S connector
3 Starter
1
End Of Sie
3
2
9.8—11.7 N·m
{100—120 kgf·cm,
87—104 in·lbf}
atraaw00000532
STARTER INSPECTION[AJ (3.0L Duratec)]

id0119a1800300
On-vehicle Inspection
2. The starter is normal if it rotates smoothly and without any noise when the engine is cranked.
• If the starter does not operate, inspect the following:
— Remove the starter, and inspect the starter unit.
— Inspect the related wiring harnesses, the ignition switch, and the transaxle range switch.
No-load Test
2. Connect the starter, battery, and a tester as
IG SW TESTER
3. Operate the starter and verify that it rotates
A
smoothly.
• If the starter does not rotate smoothly, inspect B
the starter unit. M TESTER

4. Measure the voltage and current while the starter S TERMINAL V BATTERY
is operating. STARTER
starter.
Starter no-load test voltage

atraaw00000533
11 V
Starter no-load test current

90 A or less
End Of Sie
01-19B–2
CRUISE CONTROL SYSTEM [L3]
01-20A CRUISE CONTROL SYSTEM [L3]

CRUISE CONTROL SWITCH INSPECTION
[L3] . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-20A–1
End of Toc
CRUISE CONTROL SWITCH INSPECTION[L3]
WM: CRUISE CONTROL SWITCH
id0120a2800100
1. Disconnect the negative battery cable. 01
2. Remove the driver-side air bag module. (See 08-10-5 DRIVER-SIDE AIR BAG MODULE REMOVAL/
INSTALLATION.)
3. Disconnect the cruise control switch connector. (See 09-20-9 AUDIO CONTROL SWITCH REMOVAL/
INSTALLATION.)
4. Inspect for resistance and continuity between the cruise control switch terminals using an ohmmeter.
• If not as specified, replace the cruise control switch. (See 09-20-9 AUDIO CONTROL SWITCH REMOVAL/
INSTALLATION.)
: Continuity : Resistance
CRUISE Terminal
CONTROL MAIN Switch position
SWITCH D E C
D Cruise control main
switch held at on
CANCEL SWITCH CANCEL switch
R1
held at on
SET/COAST SET/COAST
SWITCH R2
switch held at on
E
RESUME/ACCEL
RESUME/ACCEL
switch held at on R3
SWITCH
Neutral
C R1: 215.6—224.4 ohms R2: 127.4—132.6 ohms
R3: 66.64—69.36 ohms
A B C D E F G H
aesffw00000159
End Of Sie
01-20A–1
CRUISE CONTROL SYSTEM [AJ (3.0L Duratec)]
01-20B CRUISE CONTROL SYSTEM [AJ (3.0L Duratec)]

CRUISE ACTUATOR BRAKE SWITCH 2
REMOVAL/INSTALLATION REMOVAL/NSTALLATION
ACTUATOR CABLE
REMOVAL/INSTALLATION
[AJ (3.0L Duratec)] . . . . . . . . . . . . . . . . 01-20B–2
01
End of Toc
CRUISE ACTUATOR REMOVAL/INSTALLATION[AJ (3.0L Duratec)]
SOKYU_WM: CRUISE ACTUATOR
id0120a4105000
1. Release the actuator cable cap.
(1) Squeeze the actuator cable cap retaining tab.
(2) Rotate the actuator cable cap.
atraaw00003241
2. Remove the actuator cable.

(1) Depress the spring retainer.
(2) Slide the core wire end out of the cruise
control servo pulley and remove the actuator
cable.
atraaw00003242
3. Remove the cruise actuator.

(1) Disconnect the cruise actuator connector.
(2) Separate the wire harness from the bracket.
(3) Remove the nuts.
atraaw00003243
4. Remove the bolts and separate the cruise

actuator from the bracket.
End Of Sie
SOKYU_WM: ACTUATOR CABLE
atraaw00003244
01-20B–1
CRUISE CONTROL SYSTEM [AJ (3.0L Duratec)]
ACTUATOR CABLE REMOVAL/INSTALLATION[AJ (3.0L Duratec)]
id0120a4105200
1. Disconnect the actuator cable from the throttle
control linkage and bracket. (AJ (3.0L Duratec))
(1) Disconnect the cable from the throttle control
linkage.
(2) Squeeze the tabs and disconnect the actuator
cable from the bracket.
atraaw00003246
2. Release the actuator cable cap.

(1) Depress the actuator cable cap retaining tab.
(2) Rotate the actuator cable cap.
3. Remove the actuator cable.

(1) Depress the spring retainer.
(2) Slide the core wire end out of the cruise
control servo pulley and remove the actuator
cable.
End Of Sie
BRAKE SWITCH 2 REMOVAL/NSTALLATION[AJ (3.0L Duratec)]

id0120a4106000
Removal
2. Remove the brake switch 2.
(1) Disconnect the brake switch 2 connector.
(2) Rotate counterclockwise 45 degrees and
remove the brake switch 2.
01-20B–2
CONTROL SYSTEM [L3]
01-40A CONTROL SYSTEM [L3]

ENGINE CONTROL SYSTEM WIRING MANIFOLD ABSOLUTE PRESSURE
DIAGRAM[L3] . . . . . . . . . . . . . . . . . . . . 01-40A–2 (MAP) SENSOR INSPECTION[L3] . . . . 01-40A–28
CONTROL SYSTEM LOCATION THROTTLE POSITION (TP) SENSOR
INDEX[L3] . . . . . . . . . . . . . . . . . . . . . . . 01-40A–6 INSPECTION[L3] . . . . . . . . . . . . . . . . . . 01-40A–29
PCM REMOVAL/INSTALLATION ACCELERATOR PEDAL POSITION
[L3] . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-40A–7 (APP) SENSOR INSPECTION[L3]. . . . . 01-40A–31
PCM INSPECTION[L3] . . . . . . . . . . . . . . 01-40A–7 HEATED OXYGEN SENSOR (HO2S) 01
PCM CONFIGURATION[L3] . . . . . . . . . . 01-40A–22 INSPECTION[L3] . . . . . . . . . . . . . . . . . . 01-40A–33
POWER STEERING PRESSURE (PSP) CRANKSHAFT POSITION (CKP)
SWITCH INSPECTION[L3] . . . . . . . . . . 01-40A–22 SENSOR REMOVAL/INSTALLATION
ENGINE COOLANT TEMPERATURE (ECT) [L3] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-40A–37
SENSOR REMOVAL/INSTALLATION CRANKSHAFT POSITION (CKP)
[L3] . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-40A–24 SENSOR INSPECTION[L3] . . . . . . . . . . 01-40A–38
ENGINE COOLANT TEMPERATURE (ECT) CAMSHAFT POSITION (CMP) SENSOR
SENSOR INSPECTION[L3] . . . . . . . . . 01-40A–24 REMOVAL/INSTALLATION[L3] . . . . . . . 01-40A–40
MASS AIR FLOW (MAF) SENSOR CAMSHAFT POSITION (CMP) SENSOR
INSPECTION[L3] . . . . . . . . . . . . . . . . . 01-40A–25 INSPECTION[L3] . . . . . . . . . . . . . . . . . . 01-40A–40
INTAKE AIR TEMPERATURE (IAT) KNOCK SENSOR (KS)
SENSOR INSPECTION[L3] . . . . . . . . . 01-40A–27 REMOVAL/INSTALLATION[L3] . . . . . . . 01-40A–41
MANIFOLD ABSOLUTE PRESSURE (MAP) KNOCK SENSOR (KS)
SENSOR REMOVAL/INSTALLATION INSPECTION[L3] . . . . . . . . . . . . . . . . . . 01-40A–42
[L3] . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-40A–28
End of Toc
NG: ENGINE CONTROL SYSTEM
01-40A–1
CONTROL SYSTEM [L3]
ENGINE CONTROL SYSTEM WIRING DIAGRAM[L3]
id0140a7100400
With Immobilizer System
a
1AX
COOLING FAN RELAY No.1
b 1D
1BE
c 1W
1BA
1BD
1AE FUEL INJECTOR No.1
2BB
1AH FUEL INJECTOR No.2
MAF/IAT
SENSOR 2BC
1AC FUEL INJECTOR No.3
2BD
1BC FUEL INJECTOR No.4
2AZ
1AA
1Y
1AW
APP
SENSOR 2G FRONT HO2S
1I
HEATER
1AG REAR HO2S HEATER
2C
1AK
2BA
ECT SENSOR
2AK A/C RELAY
PCM
2AX 1AN
MAP FUEL PUMP RELAY

2AL
SENSOR
2AT
1AR
2AA
REAR HO2S 1AT
2AH
STARTER
2AD RELAY
FRONT STARTER
2AC
HO2S
2Z 1AB
TR SWITCH
DRIVE-BY-WIRE
RELAY
2AB 1BF
b a
1AY
2T MAIN
CKP SENSOR RELAY
2U
IGNITION
SWITCH
2X
CMP SENSOR
2Y
e c
BATTERY
2R
KS
2Q
d a b c
atraaw00001258
01-40A–2
CONTROL SYSTEM [L3]
BRAKE LIGHT
d a b c e
BRAKE SWITCH No.1 EGR VALVE

1AU
2AU
REFRIGERANT PRESSURE
SWITCH (HIGH AND LOW)
1AP 2AR
A/C
SWITCH REFRIGERANT PRESSURE 2AY
SWITCH (MIDDLE)
1R
PSP SWITCH 2AV 01
2S
1AM PURGE SOLENOID VALVE

CAN 2AN
1AI VARIABLE INTAKE AIR SOLENOID VALVE
2AJ
GENERATOR 2AM VARIABLE TUMBLE SOLENOID VALVE
2AI
OCV
2I 2AF
2O
TP SENSOR
1BB
2M
1AZ
2K
1BH
1M
INPUT/TURBINE
SPEED SENSOR
1Q
1BG SECURITY LIGHT
1A
O/D OFF SWITCH 1AS
PCM COIL (IMMOBILIZER
1O SYSTEM)
1AO
1L
2BE IGNITION COIL No.1
1P
1K 2BF IGNITION COIL No.2

TR SWITCH
1J
2BG IGNITION COIL No.3
1N
2BH IGNITION COIL No.4
BRAKE LIGHT 1S
a
SHIFT SOLENOID A
1E 2AQ GENERATOR
SHIFT SOLENOID B
1F
SHIFT SOLENOID C 2B
1G THROTTLE VALVE
TCC CONTROL SOLENOID VALVE ACTUATOR
1H 2A
3-2 TIMING SOLENOID
1C
PRESSUE CONTROL SOLENOID
1B
TFT SENSOR
1U
BRAKE SWITCH No.2

Z
CRUISE SET
AF
INDICATOR LIGHT
CRUISE CONTROL SWITCH
AD
AJ
aesffw00000482
01-40A–3
CONTROL SYSTEM [L3]
Without Immobilizer System
a
1AX
b 1D
1BE
c 1W
1BA
1BD
1AE FUEL INJECTOR No.1
2BB
1AH FUEL INJECTOR No.2
MAF/IAT
SENSOR 2BC
1AC FUEL INJECTOR No.3
2BD
1BC FUEL INJECTOR No.4
2AZ
1AA
1Y
1AW
APP
SENSOR 2G FRONT HO2S
1I
HEATER
1AG REAR HO2S HEATER
2C
1AK
2BA
ECT SENSOR
2AK A/C RELAY
PCM
2AX 1AN
MAP FUEL PUMP RELAY

2AL
SENSOR
2AT
1AQ
2AA
REAR HO2S 1AT
2AH
STARTER
2AD
FRONT
2AC
HO2S
2Z
DRIVE-BY-WIRE
RELAY
2AB 1BF
b a
1AY
2T MAIN
CKP SENSOR RELAY
2U
IGNITION
SWITCH
2X
CMP SENSOR
2Y
e c
BATTERY
2R
KS
2Q
d a b c
atraaw00001260
01-40A–4
CONTROL SYSTEM [L3]
BRAKE LIGHT
d a b c e
BRAKE SWITCH No.1 EGR VALVE

1AU
A/C 2AU
SWITCH
1AP 2AR
REFRIGERANT PRESSURE 2AY
SWITCH (MIDDLE)
PSP SWITCH
1R
2AV 01
2S
1AM PURGE SOLENOID VALVE

CAN 2AN
1AI VARIABLE INTAKE AIR SOLENOID VALVE
2AJ
GENERATOR 2AM VARIABLE TUMBLE SOLENOID VALVE
2AI
OCV
2I 2AF
2O
TP SENSOR
1BB
2M
AZ
2K
BH
1M
INPUT/TURBINE
SPEED SENSOR
1Q
1A
PCM
O/D OFF SWITCH
1O
1L
2BE IGNITION COIL No.1
1P
1K 2BF IGNITION COIL No.2

TR SWITCH
1J
2BG IGNITION COIL No.3
1N
2BH IGNITION COIL No.4
BRAKE LIGHT 1S
a
SHIFT SOLENOID A
1E 2AQ GENERATOR
SHIFT SOLENOID B
1F
SHIFT SOLENOID C 2B
1G THROTTLE VALVE
TCC CONTROL SOLENOID VALVE ACTUATOR
1H 2A
3-2 TIMING SOLENOID
1C
PRESSUE CONTROL SOLENOID
1B
TFT SENSOR
1U
BRAKE SWITCH No.2

Z
CRUISE SET
AF
INDICATOR LIGHT
CRUISE CONTROL SWITCH
AD
AJ
aesffw00000483
End Of Sie
WM: ENGINE CONTROL SYSTEM
01-40A–5
CONTROL SYSTEM [L3]
CONTROL SYSTEM LOCATION INDEX[L3]
id0140a7804100
9
12
8
1 5
7
10
6
4 11
3
atraaw00001266
1 PCM 6 CKP sensor

(See 01-40A-7 PCM INSPECTION[L3].) (See 01-40A-38 CRANKSHAFT POSITION (CKP)
2 MAF/IAT sensor SENSOR INSPECTION[L3].)
(See 01-40A-27 INTAKE AIR TEMPERATURE (IAT) (See 01-40A-37 CRANKSHAFT POSITION (CKP)
SENSOR INSPECTION[L3].) SENSOR REMOVAL/INSTALLATION[L3].)
(See 01-40A-25 MASS AIR FLOW (MAF) SENSOR 7 CMP sensor
INSPECTION[L3].) (See 01-40A-40 CAMSHAFT POSITION (CMP)
3 TP sensor SENSOR INSPECTION[L3].)
(See 01-40A-29 THROTTLE POSITION (TP) 8 Knock sensor
SENSOR INSPECTION[L3].) (See 01-40A-42 KNOCK SENSOR (KS)
4 MAP sensor INSPECTION[L3].)
(See 01-40A-28 MANIFOLD ABSOLUTE (See 01-40A-41 KNOCK SENSOR (KS) REMOVAL/
PRESSURE (MAP) SENSOR INSPECTION[L3].) INSTALLATION[L3].)
5 ECT sensor 9 HO2S
(See 01-40A-24 ENGINE COOLANT (See 01-40A-33 HEATED OXYGEN SENSOR
TEMPERATURE (ECT) SENSOR REMOVAL/ (HO2S) INSPECTION[L3].)
INSTALLATION[L3].) 10 PSP switch
(See 01-40A-24 ENGINE COOLANT (See 01-40A-22 POWER STEERING PRESSURE
TEMPERATURE (ECT) SENSOR (PSP) SWITCH INSPECTION[L3].)
INSPECTION[L3].) 11 Main relay
(See 09-21-2 RELAY INSPECTION.)
12 APP sensor
(See 01-13A-10 ACCELERATOR PEDAL
End Of Sie
WM: PCM
01-40A–6
CONTROL SYSTEM [L3]
PCM REMOVAL/INSTALLATION[L3]
id0140a7802400
Caution
• For PCM replacement, set up the IDS/PDS and perform the PCM configuration.

2. Remove the passenger-side cowl grill. (See 09-16-2 COWL GRILLE REMOVAL/INSTALLATION)
1 PCM 01
2
2 PCM bracket 7.8—10.8
{80—110, 70—95}

End Of Sie
1
7.8—10.8
{80—110, 70—95}
2
atraaw00002402
PCM INSPECTION[L3]
id0140a7802500
Using SST (IDS/PDS)
Note
• PIDs for the following parts are not available on this model. Go to the appropriate part inspection page.
— CMP sensor
— Main relay
1. Connect the SST (IDS/PDS) to the DLC-2.

2. Turn the ignition switch to ON position.
3. Measure the PID value.
• If PID value is not within the specification,
follow the instructions in Action column.
Note
• The PID/DATA MONITOR function monitors
the calculated value of the input/output
signals in the PCM. Therefore, an output
device malfunction is not directly indicated
DLC-2
as a malfunction of the monitored value for
aesffw00000044
the output device. If a monitored value of an
output device is out of specification, inspect
the monitored value of the input device related to the output control.
• For input/output signals except those of the monitoring items, use a voltmeter to measure the PCM
terminal voltage.
• The simulation items that are used in the ENGINE CONTROL SYSTEM OPERATION INSPECTION are
as follows.
— ACCS, ALTF, ARPMDES, EVAPCP, FAN1, FAN2, FP, FUELPW1, GENVDSD, HTR11, HTR12, IMRC,
IMTV, INJ_1, INJ_2, INJ_3, INJ_4, LPS, SEGRP, SOL 12S, SOL 23S, SOL 32T, SOL 34S, SOL TCC,
test, VT DUTY1 Wt
01-40A–7
CONTROL SYSTEM [L3]
PID/DATA monitor table (reference)
Monitor item Unit/ Condition/Specification PCM
Action
(Definition) Condition (Reference) terminal
A/C switch and fan switch ON at
AC_REQ ignition switch ON: On
ON/OFF Inspect A/C switch. 1AP
(A/C request signal) A/C switch OFF at ignition switch
ON: Off
Ignition switch ON: OFF Inspect following PIDs: RPM, ECT,
ACCS
ON/OFF A/C switch ON and fan switch ON at TR. 1AN
(A/C relay)
idle: ON Inspect A/C relay.
2Z
AFR (Air/fuel ratio) — Target air-oil ratio is displayed • HO2S 2AC
2AD
2Z
AFR_ACT
— Actual air-oil ratio is displayed • HO2S 2AC
(Actual air/fuel ratio)
2AD
Ignition switch ON: 0%
ALTF Inspect following PIDs: IAT, ECT,
Idle: 0—100%
(Generator field coil % RPM, VPWR, ALTT V. 2AQ
Just after A/C switch ON and fan
control duty value) Inspect generator.
switch ON at idle: Duty value rises
ALTT V Ignition switch ON: 0 V
(Generator output V Idle: Approx. 14.9 V*1 (E/L not Inspect generator. 2AM
voltage) operating)
APP Inspect following PIDs: APP1, APP2.
APP released: 0% 1Y
(Accelerator pedal % Inspect accelerator pedal position
APP open: 100% 1AG
position) sensor.
APP released: 31.0—32.4%
APP 1 %
APP open: 69.8—81.8% Inspect accelerator pedal position
(Accelerator pedal 1Y
APP released: Approx. 1.6 V sensor.
position sensor 1) V
APP depressed: Approx. 3.9 V
APP released: 20.2—21.4%
APP 2 %
APP depressed: 58.8—70.8% Inspect accelerator pedal position
(Accelerator pedal 1AG
APP released: Approx. 1.03 V sensor.
position sensor 2) V
APP depressed: Approx. 3.35 V
No load: 650—750 rpm Inspect following PIDs: IAT, RPM,
ARPMDES E/L operating: 650—750 rpm MAP, ECT, MAF, INGEAR, TR, PSP,
RPM —
(Target engine speed) P/S operating: 650—750 rpm ALTT V.
A/C ON: 650—750 rpm Inspect CKP sensor.
BOO Brake pedal depressed: ON
ON/OFF Inspect brake switch. 1AU
(Brake switch) Brake pedal released: OFF
BPA
Brake pedal depressed: ON
(Brake pressure ON/OFF Inspect brake switch. —
Brake pedal released: OFF
applied switch)
CATT11_DSD
Perform applicable DTC
(Desired catalyst Indicate the estimated catalytic
°C troubleshooting. —
temperature bank one, converter temperature
(See 01-02A-13 DTC TABLE[L3])
sensor one)
CHRGLP Perform applicable DTC
Ignition switch ON: ON
(Generator warning ON/OFF troubleshooting. —
Idle: OFF
light) (See 01-02A-13 DTC TABLE[L3].)
Refrigerant pressure switch (middle)
COLP
ON *2 at idle: ON
(Refrigerant pressure ON/OFF Inspect refrigerant pressure switch. 1R
Refrigerant pressure switch (middle)
switch (middle)) *3
OFF at idle: OFF
DTCCNT Perform applicable DTC
(Number of DTC — — troubleshooting. —
detected) (See 01-02A-13 DTC TABLE[L3].)
ECT 20 °C {68 °F}: 20 °C {68 °F}
ECT °C °F
ECT 60 °C {140 °F}: 60 °C {140 °F}
(Engine coolant Inspect ECT sensor. 2AK
temperature) ECT 20 °C {68 °F}: 3.04—3.14 V
V
ECT 60 °C {140 °F}: 1.29—1.39 V
EQ_RAT11 Perform applicable DTC 2Z
(Equivalence ratio — Idling after warm-up: Approx. 1 troubleshooting. 2AC
(lambda)) (See 01-02A-13 DTC TABLE[L3].) 2AD
01-40A–8
CONTROL SYSTEM [L3]
Action
EQ_RAT11_DSD Perform applicable DTC 2Z
(Desired equivalence — Idling after warm-up: Approx. 1 troubleshooting. 2AC
ratio (lambda)) (See 01-02A-13 DTC TABLE[L3].) 2AD
ETC_ACT Perform applicable DTC
2A
(Electronic throttle ° Indicate the desired TP by angle troubleshooting.
2B
control actual) (See 01-02A-13 DTC TABLE[L3].)
ETC_DSD
(Electronic throttle
% Indicate the desired TP by percent Inspect following PIDs:APP1, APP2,
ETC_ACT.
1Y 01
control desired) ° Indicate the desired TP by angle Inspect TP sensor.
1AG
EVAPCP Inspect following PIDs: IAT, RPM,
Ignition switch ON: 0%
(Purge solenoid valve % ECT, MAF, O2S11, INGEAR, TR, 2AN
Idle: 0%
duty value) VPWR.
Inspect following PIDs: RPM, ECT,
FAN1 ECT below 100 °C {212 °F}: OFF
ON/OFF COLP, test. 1D
(Cooling fan control) Others: ON
Inspect cooling fan relay.
ECT below 108 °C {226 °F}: OFF
A/C operating, refrigerant pressure Inspect following PIDs: RPM, ECT,
FAN2
ON/OFF switch (middle) is OFF, and ECT COLP, test. 1W
(Cooling fan control)
below 108 °C {226 °F}: OFF Inspect cooling fan relay.
Others: ON
Ignition switch ON: OFF
FP Inspect following PIDs: RPM. 1AQ*4
ON/OFF Idle: ON
(Fuel pump relay) Inspect fuel pump relay. 1AR*5
Cranking: ON
Inspect following PIDs: IAT, MAF, 2AZ
FUELPW Ignition switch ON: 0 ms MAP, ECT, RPM, O2S11, O2S12, 2BB
ms
(Fuel injector duration) Idle (after warm up): approx. 2.5 ms INGEAR, TR, PSP, VPWR, ALTT V. 2BC
Inspect fuel injector. 2BD
OL/CL/OL- Inspect following PIDs: IAT, MAF,
FUELSYS Drive/OL- Ignition switch ON: OL_Drive MAP, ECT, RPM, O2S11, O2S12,
—
(Fuel system status) Fault/CL- Idle (after warm up): CL INGEAR, TR, PSP, VPWR, ALTT V.
Fault Inspect fuel injector.
GEAR (See 05-02A-46 PID/DATA MONITOR INSPECTION[GF4AX-EL])
GENVDSD Ignition switch ON: 0 V Perform applicable DTC
(Generator voltage V Idle: Approx. 14.9 V (E/L not troubleshooting. —
desired) operating) (See 01-02A-13 DTC TABLE[L3].)
HTM_CNT (See 05-02A-46 PID/DATA MONITOR INSPECTION[GF4AX-EL])
HTM_DIS (See 05-02A-46 PID/DATA MONITOR INSPECTION[GF4AX-EL])
HTR11 Inspect following PIDs: IAT, MAF,
ON/OFF Idle (after warm up): ON⇔OFF 2G
(HO2S heater (front)) ECT, RPM.
Ignition switch ON: OFF (HO2S
HTR12 Inspect following PIDs: IAT, MAF,
ON/OFF heater not operating) 2C
(HO2S heater (rear)) ECT, RPM.
Idle: ON (HO2S heater operating)
°C °F Indicate the IAT.
IAT IAT 20 °C {68 °F}: Approx. 2.4—2.6
V Inspect IAT sensor. 1AH
(Intake air temperature) V
IAT 30 °C {86 °F}: Approx. 1.7—1.9
V
IMRC Engine speed is below approx. Inspect following PIDs: ECT, RPM.
(Variable tumble ON/OFF 3,750 rpm: ON Inspect variable tumble solenoid 2AI
solenoid valve) Others: OFF valve.
IMTV Engine speed is below approx.
Inspect following PIDs: RPM.
(Variable Intake air ON/OFF 4,600 rpm: ON 2AJ
Inspect VIS control solenoid valve.
control solenoid valve) Others: OFF
INGEAR
Driving range: OFF Perform applicable DTC
(Load/no load ON/OFF —
Others: ON troubleshooting.
condition)
IVS IDLE/ OFF CTP: IDLE Perform applicable DTC 1Y
(CTP condition) IDLE Others: OFF IDLE troubleshooting. 1AG
KNOCKR Ignition switch ON: 0° 2Q
° Inspect knock sensor.
(Knocking retard) Idle: 0° 2R
LINEDES (See 05-02A-46 PID/DATA MONITOR INSPECTION[GF4AX-EL])
LOAD Ignition switch ON: 0%
% Inspect MAF sensor. —
(Engine load) Idle (after warm up): approx.19%
01-40A–9
CONTROL SYSTEM [L3]
Action
LONGFT1 Idle (after warm up): approx. –14—
% troubleshooting. —
(long term fuel trim) 14%
(See 01-02A-13 DTC TABLE[L3].)
LPS
(Pressure control (See 05-02A-46 PID/DATA MONITOR INSPECTION[GF4AX-EL])
solenoid)
Ignition switch ON: approx. 0 g/s
g/s
MAF Idle (after warm up): approx. 1.5 g/s
Inspect MAF sensor. 1AC
(Mass airflow) Ignition switch ON: approx. 0.7 V
V
Idle (after warm up): approx. 1.3 V
Ignition switch ON (at sea level):
MAP kPa, inHg
approx. 101 kPa {29.8 inHg}
(Manifold absolute Inspect MAP sensor. 2AL
pressure) Ignition switch ON (at sea level):
V
approx. 4.1 V
MIL Perform applicable DTC
Ignition switch ON: ON
(Malfunction indicator ON/OFF troubleshooting. —
Idle: OFF
lamp) (See 01-02A-13 DTC TABLE[L3].)
MIL_DIS
(Travelled distance No DTC: 0 km {0 mile}
km, mile troubleshooting. —
since the MIL DTC detected: Not 0 km {0 mile}
illuminated)
NUMKEYS
Indicate the number of the keys
(Number of keys stored — — —
stored module
in module)
2Z
O2S11 Ignition switch ON: -1.0— 1.0 A
A Inspect HO2S (front). 2AC
(front oxygen sensor) Idle (After warm up): 0.25 A more
2AD
O2S12 Idle (After warm up): Alternates
V Inspect HO2S (rear). 2AH
(Rear oxygen sensor) between 0 and 1.0
PSP Steering wheel in straight ahead
(Power steering Low/High position: Low Inspect PSP switch. 2S
pressure switch) Others: High
RO2FT1
Idle (after warm up): approx. – Perform applicable DTC
(Rear oxygen sensor — —
0.03—0.03 troubleshooting.
fuel trim)
RPM
rpm Indicate the engine speed Inspect CKP sensor. 2U
(Engine speed)
Press ON/OFF: Approx. 0 V
SCCS Press CANCEL: Approx. 1.1 V
(Speed control V Press SET/COAST: Approx. 3.1 V Inspect cruise control switch. —
command switch) Press RES/ACCEL: Approx. 4.2 V
Others: Approx. 5.0 V
2AU
SEGRP Ignition switch ON: 0 step Inspect following PIDs: MAF, ECT,
2AR
(EGR valve (stepping — Idle: 0 step RPM, VSS.
2AY
motor) position) Cranking: 0—60 steps Inspect EGR valve.
2AV
2AU
SEGRP DSD
Inspect following PIDs: MAF, ECT, 2AR
(Desired SEGRP valve % Idle: 0%
RPM, VSS. 2AY
position)
2AV
SELTESTDTC Perform applicable DTC
(Diagnostic trouble — — troubleshooting. —
codes) (See 01-02A-13 DTC TABLE[L3].)
SHRTFT1 Idle (after warm up): approx.–30—
% troubleshooting. —
(Short term fuel trim) 25%
SHRTFT12 Perform applicable DTC
Idle (after warm up): Approx.–30—
(Short term fuel trim % troubleshooting. —
25%
bank 1 sensor 2) (See 01-02A-13 DTC TABLE[L3].)
SOL 12S
(See 05-02A-46 PID/DATA MONITOR INSPECTION[GF4AX-EL])
(Shift solenoid A)
SOL 23S
(Shift solenoid B)
01-40A–10
CONTROL SYSTEM [L3]
Action
SOL 32T
(3-2 timing solenoid (See 05-02A-46 PID/DATA MONITOR INSPECTION[GF4AX-EL])
valve)
SOL 34S
(Shift solenoid C)
SOL TCC
(TCC control solenoid
valve)
(See 05-02A-46 PID/DATA MONITOR INSPECTION[GF4AX-EL]) 01
2BE
Inspect following PIDs: MAF, ECT,
SPARKADV Ignition switch ON: BTDC 0° 2BF
° RPM, INGEAR, TR, PSP, VPWR.
(Ignition timing) Idle: BTDC approx. 8° 2BG
Inspect ignition timing.
2BH
TCIL
(O/D OFF indicator (See 05-02A-46 PID/DATA MONITOR INSPECTION[GF4AX-EL])
light)
TCS
(O/D OFF switch)
test
ON/OFF — — —
(Test mode)
TFT
(Transaxle fluid (See 05-02A-46 PID/DATA MONITOR INSPECTION[GF4AX-EL])
temperature)
TFTV
(Transaxle fluid signal (See 05-02A-46 PID/DATA MONITOR INSPECTION[GF4AX-EL])
voltage)
TIRESIZE Indicate the tire circumference
rev/mile — —
(Tire Size (rev / mile)) length
TP REL
APP released: Approx. 10%
(Relative throttle % Inspect TP sensor. —
APP depressed: Approx. 93%
position)
APP released: 8—12%
%
TP 1 APP depressed: 88—94%
Inspect TP sensor. 2M
(TP) APP released: 0.4—0.6 V
V
APP depressed: 4.4—4.7 V
APP released: 88—92%
%
TP 2 APP depressed: 6—12%
Inspect TP sensor. 2I
(TP) APP released: 4.4—4.6 V
V
APP depressed: 0.3—0.6 V
TPCT
2I
(TP sensor voltage at V Approx. 0.5 V Inspect TP sensor.
2M
CTP)
TR
(Transaxle range)
TRD
(TR switch D range)
TRL
(TR switch 1 range)
TRN
(TR switch N range)
TRP
(TR switch P range)
TRR
(TR switch R position)
TRS
(TR switch 2 range)
TSS
(Input/turbine speed)
VPWR
(Battery positive V Indicate the battery voltage • Battery 1BA
voltage)
01-40A–11
CONTROL SYSTEM [L3]
Action
Vehicle speed 20 kph {12 mph}:
VSS 20 kph {12 mph}
kph, mph troubleshooting. —
(Vehicle speed) Vehicle speed 40 kph {25 mph}:
20 kph {12 mph}
VT ACT1 Inspect following PIDs: ECT, RPM.
° Idle: Approx. 0° 2AF
(Actual valve timing) Inspect OCV.
VT DIFF1
(Difference between Inspect following PIDs: ECT, RPM.
° Idle: Approx. 0° 2AF
target and actual valve Inspect OCV.
timing)
VT DUTY1
Inspect following PIDs: ECT, RPM.
(Oil control valve duty % Idle: Approx. 11.5% 2AF
Inspect OCV.
value)
*1 : Calculated value; differs from terminal voltage

*2 : Refrigerant pressure switch (middle) turns on when the refrigerant pressure is 1.69—1.84 MPa {17.3—18.7
kgf/cm2, 247—265 psi}
3
* : Refrigerant pressure switch (middle) turns off when the refrigerant pressure is 1.26—1.49 MPa {12.9—15.1
kgf/cm2, 184—214 psi}
4
* : With immobilizer sysetem
*5 : Without immobilizer sysetem
• Following PIDs are for the ATX models. If inspects for following PIDs, (See 05-02A-46 PID/DATA MONITOR
INSPECTION[GF4AX-EL].)
Without Using the SST
Note
• The PCM terminal voltage can vary with the conditions when measuring and changes due to aged
deterioration on the vehicle, causing false diagnosis. Therefore determine comprehensively where the
malfunction occurs among the input systems, output systems, and the PCM.
PCM
atraaw00001270
Voltage
Terminal Signal Connected to Test condition Inspection item
(V)
Ignition switch to the ON position B+ • Main relay
• Battery
1A Battery voltage Main relay
Ignition switch off after 90 s Below 1.0 • Related wiring
harness
Ignition switch ON Below 1.0 • Pressure control
Pressure control Pressure control solenoid
1B
solenoid solenoid idle (after warm up) B+ • Related wiring
harness
• 3-2 shift solenoid
3-2 timing Changing the
1C 3-2 timing solenoid idle B+ • Related wiring
solenoid speed
harness
Cooling fan
operate
Below 1.0 • Cooling fan relay
Cooling fan control
1D Cooling fan relay idle • Related wiring
(Main) Cooling fan not
B+ harness
operate
01-40A–12
CONTROL SYSTEM [L3]
Voltage
(V)
• Shift solenoid A
D range,
1E Shift solenoid A Shift solenoid A idle B+ • Related wiring
2 range
harness
• Shift solenoid B
1F Shift solenoid B Shift solenoid B idle 1GR, 2GR B+ • Related wiring
harness
1G Shift solenoid C Shift solenoid C idle D range B+

• Shift solenoid C
• Related wiring
01
harness
• TCC control solenoid
TCC control TCC control
1H Operation torque converter clutch B+ • Related wiring
solenoid solenoid
harness
• Related wiring
1I APP sensor ground APP sensor Under any condition Below 1.0
harness
• transaxle range
Ignition switch
transaxle range transaxle range switch
1J is turned to the R range B+
switch switch • Related wiring
ON position.
harness
• transaxle range
Ignition switch
1K is turned to the 1 range B+
ON position.
harness
• transaxle range
Ignition switch
1L is turned to the D range B+
ON position.
harnesses
• Input/turbine speed
• Inspect using the wave profile.
Input/turbine speed Input/turbine sensor
1M (See 01-40A-19 Inspection Using An
sensor (+) speed sensor • Related wiring
Oscilloscope (Reference).)
harness
• transaxle range
Ignition switch
1N is turned to the P range B+
ON position.
harnesses
Ignition switch D3 range Below 1.0 • Selector lever
1O D3 range switch D3 range switch is turned to the • Related wiring
ON position. Except above B+ harness
• transaxle range
Ignition switch
1P is turned to the 2 range B+
ON position.
harnesses
• Input/turbine speed
Input/turbine speed Input/turbine sensor
1Q (See 01-40A-19 Inspection Using An
sensor (–) speed sensor • Related wiring
harness
Refrigerant
pressure is
above 1.52 Below 1.0
MPa {15.5 kgf/ • Refrigerant pressure
Refrigerant Refrigerant cm2, 220 psi} switch
1R pressure switch pressure switch A/C ON
Refrigerant • Related wiring
(medium) (medium)
pressure is harness
below 1.23 B+
MPa {12.5 kgf/
cm2, 178 psi}
• transaxle range
Ignition switch
1S is turned to the N range B+
ON position.
harnesses
1T — — — — —
01-40A–13
CONTROL SYSTEM [L3]
Voltage
(V)
TFT is 20 °C Approx.
{68 °F} 3.5
Ignition switch • TFT sensor
1U ATF temperature TFT sensor is turned to the • Related wiring
{104 °F} 2.7
ON position. harness
{140 °F} 1.9
1V — — — — —
Cooling fan
operate
Below 1.0 • Cooling fan relay
Cooling fan control
1W Cooling fan relay idle • Related wiring
(Transfer) Cooling fan not
B+ harness
operate
1X — — — — —
When the
accelerator Approx.
pedal is 3.9
Ignition switch depressed • APP sensor
1Y APP sensor 1 APP sensor to the ON • Related wiring
position When the harness
accelerator Approx.
pedal is 1.6
released
Brake pedal depressed B+ • Brake switch No.2
1Z Brake (No.2) Brake switch No.2 • Related wiring
Brake pedal released Below 1.0 harness
• Related wiring
1AA APP sensor ground APP sensor Under any condition Below 1.0
harness
• Starter relay
1AB*1 Starter relay control Starter relay Under any condition Below 1.0 • Related wiring
harness
Approx.
Ignition switch to the ON position
0.7 • MAF sensor
1AC MAF MAF sensor • Related wiring
Approx. harness
Idle (after warm up)
1.3
ON/OFF switch
Approx. 0
pressed in
CANCEL
Approx.
switch pressed
1.1
in
Ignition switch SET/COAST • Cruise control switch
Cruise control Cruise control Approx.
1AD to the ON switch pressed • Related wiring
switch switch 3.1
position in harnesses
RES/ACCEL
Approx.
switch pressed
4.2
in
Approx.
Except above
5.0
TFT sensor • Related wiring
1AE Sensor ground Ignition switch to the ON position Below 1.0
APP sensor harness
• Related wiring
1AF Cruise indicator Cruise indicator Ignition switch to the ON position Below 1.0
harness
When the
accelerator Approx.
pedal is 3.35
Ignition switch depressed • APP sensor
1AG APP sensor 2 APP sensor to the ON • Related wiring
position When the harness
accelerator Approx.
pedal is 1.03
released
IAT 20 °C
Ignition switch {68 °F}
2.4—2.6 • IAT sensor
1AH IAT MAF/IAT sensor to the ON • Related wiring
position IAT 30 °C harness
1.7—1.9
{86 °F}
01-40A–14
CONTROL SYSTEM [L3]
Voltage
(V)
Instrument cluster,
Because this terminal is for CAN, good/no
ABS HU/CM, • Related wiring
1AI CAN (L) good judgment by terminal voltage is not
EHPAS control harness
possible.
module
• Cruise control switch
Cruise control Cruise control
1AJ Ignition switch to the ON position Below 1.0 • Related wiring
switch (main) switch
Constant voltage Approx.
harness
• Related wiring
01
1AK APP sensor Ignition switch to the ON position
(Vref) 5.0 harness
1AL — — — — —
Instrument cluster,
Because this terminal is for CAN, good/no
ABS HU/CM, • Related wiring
1AM CAN (H) good judgment by terminal voltage is not
EHPAS control harness
possible.
module
A/C operating Below 1.0 • A/C relay
idle
1AN A/C A/C relay A/C not • Related wiring
(after warm up) B+
operating harness
Because this terminal is for communication, • Coil
Coil (Immobilizer
1AO*1 Coil good/ no good judgment by terminal voltage • Related wiring
system)
is not possible. harness
• Refrigerant pressure
Refrigerant
idle A/C switch and switch
1AP A/C on signal pressure switch Below 1.0
(after warm up) fan switch on • Related wiring
(high and low)
harness
B+ • Fuel pump relay
after 1 s
1AQ*2 Fuel pump control Fuel pump relay • Related wiring
Cranking Below 1.0
harness
idle (after warm up) Below 1.0
B+ • Fuel pump relay
after 1 s
1AR*1 Fuel pump control Fuel pump relay • Related wiring
Cranking Below 1.0
harness
idle (after warm up) Below 1.0
Because this terminal is for communication, • Coil
Coil (Immobilizer
1AS*1 Coil good/ no good judgment by terminal voltage • Related wiring
system)
is not possible. harness
Ignition switch off after 90 s B+ • Main relay
1AT Main relay control Main relay • Related wiring
Ignition switch to the ON position Below 1.0 harness
Brake pedal depressed B+ • Brake switch No.1
1AU Brake (No.1) Brake switch No.1 • Related wiring
Brake pedal released Below 1.0 harness
1AV — — — — —
Constant voltage Approx. • Related wiring
1AW APP sensor Ignition switch to the ON position
(Vref) 5.0 harness
Ignition switch off Below 1.0 • Related wiring
1AX Ignition switch Ignition switch
Ignition switch to the ON position B+ harness
Drive-by-wire Ignition switch off B+ • Related wiring
1AY Drive-by-wire relay
relay Ignition switch to the ON position Below 1.0 harness
• Related wiring
1AZ ground ground Under any condition Below 1.0
harness
• Battery
Back-up power Battery (positive
1BA Under any condition B+ • Related wiring
supply terminal)
harness
• Related wiring
1BB ground ground Under any condition Below 1.0
harness
• Related wiring
1BC ground ground Under any condition Below 1.0
harness
• Related wiring
1BD ground ground Under any condition Below 1.0
harness
01-40A–15
CONTROL SYSTEM [L3]
Voltage
(V)
Ignition switch off after 9 s Below 1.0 • Battery
1BE B+ Main relay • Related wiring
Ignition switch to the ON position B+ harness
Drive-by-wire Ignition switch off after 9 s Below 1.0 • Related wiring
1BF Drive-by-wire relay
relay Ignition switch to the ON position B+ harness
Security light Instrument cluster • Related wiring
1BG*1 control (Security light)
Ignition switch to the ON position B+
harness
• Related wiring
1BH ground ground Ignition switch to the ON position B+
harness
• Throttle actuator
Throttle actuator
2A Throttle actuator Ignition switch to the ON position B+ • Related wiring
control (+)
harness
• Throttle actuator
Throttle actuator
2B Throttle actuator Idle (after warm up) B+ • Related wiring
control (–)
harness
Idle (after warm up) Below 1.0 • HO2S (rear) heater
Rear HO2S heater HO2S (rear)
2C • Related wiring
control heater Engine speed above 4,000 rpm B+ harness
2D — — — — —
2E — — — — —
2F — — — — —
• Inspect using the wave profile. • HO2S (front) heater
Front HO2S heater HO2S (front)
2G (See 01-40A-19 Inspection Using An • Related wiring
control heater
Oscilloscope (Reference).) harness
2H — — — — —
Ignition switch CTP 4.4—4.6 • TP sensor
2I TP (No. 2) TP sensor No. 2 to the ON • Related wiring
position WOT 0.3—0.6 harness
2J — — — — —
• TP sensor
Constant voltage Approx.
2K TP sensor Ignition switch to the ON position • Related wiring
(Vref) 5.0
harness
2L — — — — —
Ignition switch CTP 0.4—0.6 • TP sensor
2M TP (No. 1) TP sensor No. 1 to the ON • Related wiring
position WOT 4.4—4.7 harness
2N — — — — —
• TP sensor
2O TP sensor ground TP sensor Under any condition Below 1.0 • Related wiring
harness
2P — — — — —
(Use digital type voltmeter,
• KS
because measurement voltage Approx.
2Q Knocking (+) KS • Related wiring
will be detected less than true 4.3
harness
voltage when using analog type
voltmeter)
(Use digital type voltmeter,
• KS
because measurement voltage
2R Knocking (–) KS Below 1.0 • Related wiring
will be detected less than true
harness
voltage when using analog type
voltmeter)
Steering wheel
at straight B+ • TP sensor
2S PSP PSP switch Idle ahead position • Related wiring
While turning harness
Below 1.0
steering wheel
• Related wiring
2T Constant voltage CKP sensor Ignition switch to the ON position B+
harness
01-40A–16
CONTROL SYSTEM [L3]
Voltage
(V)
• Inspect using the wave profile. • CKP sensor
2U CKP (+) CKP sensor (See 01-40A-19 Inspection Using An • Related wiring
• Inspect using the wave profile. • CMP sensor
2V CMP (+) CMP sensor (See 01-40A-19 Inspection Using An • Related wiring
2W — — — — — 01
• Related wiring
2X Constant voltage CMP sensor Ignition switch to the ON position B+
harness
2Y — — — — —
• HO2S (front)
HO2S (front) power Approx.
2Z HO2S (front) Idle (after warm up) • Related wiring
supply 4.0
harness
• Related wiring
2AA Sensor ground HO2S (rear) Under any condition Below 1.0
harness
• Related wiring
2AB Internal ground KS, HO2S (front) Under any condition Below 1.0
harness
• HO2S (front)
Approx.
2AC HO2S (front) VSIP HO2S (front) Idle (after warm up) • Related wiring
3.6
harness
Approx.
Idle
3.8 • HO2S (front)
2AD HO2S (front) IP+ HO2S (front) • Related wiring
Approx. harness
After racing
3.1
2AE — — — — —
• Inspect using the wave profile. • OCV valve
2AF OCV control OCV (See 01-40A-19 Inspection Using An • Related wiring
2AG — — — — —
Ignition switch to the ON position Approx. 0
• HO2S (rear)
2AH Rear HO2S HO2S (rear) Alternates • Related wiring
Idle (after warm up) between 0 harness
and 1.0
ECT above 63 °C {145 °F} while • Variable tumble
B+
Variable tumble Variable tumble idling. solenoid valve
2AI
control solenoid valve ECT below 63 °C {145 °F} and • Related wiring
Below 1.0 harness
engine speed below 3,750 rpm
Engine speed: below 4,600 rpm Below 1.0 • Variable intake air
Variable intake air Variable intake air solenoid valve
2AJ
control solenoid valve Engine speed: above 4,600 rpm B+ • Related wiring
harness
ECT 20 °C 3.04—
Ignition switch {68 °F} 3.14 • ECT sensor
2AK ECT ECT sensor to the ON • Related wiring
position ECT 60 °C 1.29— harness
{140 °F} 1.39
Ignition switch to the ON position Approx.
(at sea level) 4.1 • MAP sensor
Manifold absolute
2AL MAP sensor • Related wiring
pressure Approx.
idle (after warm up) harness
1.4
• Inspect using the wave profile. • Generator
Generator output Generator
2AM (See 01-40A-19 Inspection Using An • Related wiring
voltage (terminal P)
• Inspect using the wave profile. • Purge solenoid valve
Purge solenoid
2AN Purge control (See 01-40A-19 Inspection Using An • Related wiring
valve
2AO — — — — —
2AP — — — — —
01-40A–17
CONTROL SYSTEM [L3]
Voltage
(V)
• Following PIDs: IAT,
ECT, RPM, VPWR,
Generator field coil Generator ALTT V.
2AQ (See 01-40A-19 Inspection Using An
control (terminal D) • Generator
• Related wiring
harness
Ignition switch to the ON position B+ • EGR valve
EGR valve #2 coil EGR valve
2AR • Related wiring
control (terminal A) idle (after warm up) B+ harness
2AS — — — — —
• Related wiring
2AT Constant voltage MAP sensor Ignition switch to the ON position B+
harness
Ignition switch to the ON position Below 1.0 • EGR valve
2AU • Related wiring
control (terminal E) idle (after warm up) Below 1.0 harness
Ignition switch to the ON position Below 1.0 • EGR valve
2AV • Related wiring
control (terminal F) idle (after warm up) Below 1.0 harness
2AW — — — — —
• Related wiring
2AX ground MAP sensor Under any condition Below 1.0
harness
Ignition switch to the ON position B+ • EGR valve
2AY • Related wiring
control (terminal B) idle (after warm up) B+ harness
• Inspect using the wave profile. • Fuel injector No.4
2AZ Fuel injection (#4) Fuel injector No.4 (See 01-40A-19 Inspection Using An • Related wiring
• Related wiring
2BA ground ECT sensor Under any condition Below 1.0
harness
2BB Fuel injection (#1) Fuel injector No.1 (See 01-40A-19 Inspection Using An • Related wiring
2BC Fuel injection (#2) Fuel injector No.2 (See 01-40A-19 Inspection Using An • Related wiring
2BD Fuel injection (#3) Fuel injector No.3 (See 01-40A-19 Inspection Using An • Related wiring
• Inspect using the wave profile. • Ignition coil
Ignition coil (No.1
2BE IGT1 (See 01-40A-19 Inspection Using An • Related wiring
cylinders)
Ignition coil (No.2
2BF IGT2 (See 01-40A-19 Inspection Using An • Related wiring
cylinders)
Ignition coil (No.3
2BG IGT3 (See 01-40A-19 Inspection Using An • Related wiring
cylinders)
Ignition coil (No.4
2BH IGT4 (See 01-40A-19 Inspection Using An • Related wiring
cylinders)
*1 : With immobilizer sysetem

*2 : Without immobilizer sysetem
01-40A–18
CONTROL SYSTEM [L3]
Inspection Using An Oscilloscope (Reference)
Purge control signal
01
0V
atraaw00001272
PCM terminals
• 2C(+)—body ground(–)
Oscilloscope setting
• 2 V/DIV (Y), 10 ms/DIV (X), DC range
Vehicle condition
• Idle after warm up (no load, P/S off, A/C off)
OCV control signal
0V
atraaw00001273
PCM terminals
• 2E(+)—body ground(–)
• 2 V/DIV (Y), 0.8 ms/DIV (X), DC range
Vehicle condition
CMP sensor signal
0V
atraaw00001274
PCM terminals
• 2S(+)—body ground(–)
Vehicle condition
01-40A–19
CONTROL SYSTEM [L3]
CKP sensor signal
0V
atraaw00001275
PCM terminals
• 2W(+)—body ground(–)
Vehicle condition
Generator field coil control signal
0V
atraaw00001276
PCM terminals
• 2AI(+)—body ground(–)
• 0.5 V/DIV (Y), 1 ms/DIV (X), DC range
Vehicle condition
Generator output voltage signal
0V
atraaw00001277
PCM terminals
• 2AJ(+)—body ground(–)
Vehicle condition
01-40A–20
CONTROL SYSTEM [L3]
IGT1, IGT2, IGT3, IGT4 control signals
0V
01
atraaw00001278
PCM terminals
• IGT1(ignition coil No.1): 2BA(+)—body ground(–)
• IGT2(ignition coil No.2): 2AW(+)—body ground(–)
• IGT3(ignition coil No.3): 2AX(+)—body ground(–)
• IGT4(ignition coil No.4): 2AT(+)—body ground(–)
Vehicle condition
Fuel injection control
0V
atraaw00001279
PCM terminals
• Fuel Injection No.1: 2BB(+)—body ground(–)
• Fuel Injection No.2: 2BC(+)—body ground(–)
• Fuel Injection No.3: 2BD(+)—body ground(–)
• Fuel Injection No.4: 2AZ(+)—body ground(–)
Vehicle condition
HO2S (rear) heater control
0V
atraaw00001280
PCM terminals
• 2BE(+)—body ground(–)
• 2 V/DIV (Y), 1 s/DIV (X), DC range
01-40A–21
CONTROL SYSTEM [L3]
Vehicle condition
• Idle (immediately after starting the engine)
HO2S (front) heater control
0V
atraaw00001281
PCM terminals
• 2BG(+)—body ground(–)
Vehicle condition
• Idle (immediately after starting the engine)
End Of Sie
PCM CONFIGURATION[L3]
id0140a7802600
1. Connect the IDS/PDS to DLC-2.
2. After the vehicle is identified, select the following
items from the initial screen of the IDS/PDS.
• When using the IDS (notebook PC)
1. Select the “Module Programming”.
• When using the PDS (pocket PC)
1. Select “Programming”.
2. Select “Module Programming”.
3. Then, select the “Programmable Module
Installation”, “PCM” from the screen menu.
4. Retrieve DTCs using the IDS/PDS, then verify
DLC-2
that there in no DTC present.
• If a DTC is present, perform the applicable
aesffw00000044
DTC inspection.
End Of Sie
POWER STEERING PRESSURE (PSP) SWITCH INSPECTION[L3]
WM: POWER STEERING PRESSURE SWITCH
id0140a7803100
Note
1. Inspect the following if the power steering is inoperative (See 06-14-2 POWER STEERING FLUID
INSPECTION.):
• Power steering fluid level
• Power steering fluid leakage
• Power steering fluid pressure
2. Disconnect the PSP switch connector.
4. Inspect for continuity between the PSP switch terminal and GND using an ohmmeter.
• If not as specified, replace the PSP switch.
• If the PSP switch is okay, but PSP PID value is out of specification, perform the “Circuit Open Inspection”.
01-40A–22
CONTROL SYSTEM [L3]
Specification
Continuity
Condition Terminal GND
Steering wheel in straight
ahead position
While turning steering
wheel
atraaw00001315
01
Circuit Open Inspection
PSP SWITCH
atraaw00001316
PCM
atraaw00001317

2. Inspect the following harness for open or short. (Continuity check)
Open circuit
— PSP switch terminal and PCM terminal 2S
— PSP switch terminal and body ground
Short circuit
— PSP switch terminal and body ground
End Of Sie
WM: TEMPERATURE SENSOR
01-40A–23
CONTROL SYSTEM [L3]
ENGINE COOLANT TEMPERATURE (ECT) SENSOR REMOVAL/INSTALLATION[L3]
id0140a7801900
4. Disconnect the ECT sensor connector.
5. Remove the ECT sensor using the SST.
10—14 N·m
6. Install in the reverse order of removal. {102—142 kgf·cm,
89—123 in·lbf}
Tightening torque
10—14 N·m {102—142 kgf·cm, 89—123
in·lbf}
End Of Sie
49 D015 001
atraaw00002520
ENGINE COOLANT TEMPERATURE (ECT) SENSOR INSPECTION[L3]

id0140a7802000
Note
ECT Sensor Resistance Inspection

1. Drain the engine coolant. (See 01-12A-2 COOLING SYSTEM SERVICE WARNINGS[L3].)
2. Remove the ECT sensor (located above the starter).
3. Place the ECT sensor in water with a thermometer, and heat the water gradually.
4. Measure the resistance between the ECT sensor terminals A and B using an ohmmeter.
• If not as specified, replace the ECT sensor.
• If the ECT sensor is okay, but ECT PID value is out of specification, perform the “Circuit Open/Short
Inspection”.
Specification
Water temperature (°C {°F}) Resistance (kilohms)
20 {68} 35.48—39.20
70 {158} 5.07—5.60
80 {176} 3.65—4.02
01-40A–24
CONTROL SYSTEM [L3]
ECT SENSOR
B A
01
atraaw00001318
PCM
atraaw00001319

2. Inspect the following wiring harnesses for open or short. (Continuity check)
Open circuit
— ECT sensor terminal A and PCM terminal 2AK
— ECT sensor terminal B and PCM terminal 2BA
Short circuit
— ECT sensor terminal A and power supply
— ECT sensor terminal A and body ground
— ECT sensor terminal B and power supply
End Of Sie
MASS AIR FLOW (MAF) SENSOR INSPECTION[L3]
WM: MASS AIR FLOW SENSOR
id0140a7800700
Voltage Inspection
Note
1. Visually inspect for the following on the MAF sensor.

• Damage
• Cracks
• Terminal bends
• Terminal rust
— If any of the above are found, replace the MAF sensor.
— If the MAF PID value is out of specification, carry out the “Circuit Open/Short Inspection”.
01-40A–25
CONTROL SYSTEM [L3]
MAF/IAT SENSOR
(HARNESS SIDE CONNECTOR)
E D C B A
atraaw00001320
MAIN FUSE BLOCK

(FUEL PUMP RELAY)
B
A E
FRONT
D
atraaw00000831
PCM
atraaw00001321

2. Disconnect the MAF sensor connector.
Open circuit
— MAF sensor terminal A and main relay terminal A
— MAF sensor terminal B and PCM terminal 1BC
— MAF sensor terminal C and PCM terminal 1AC
Short circuit
— MAF sensor terminal A and body ground
— MAF sensor terminal C and power supply
— MAF sensor terminal C and body ground
— MAF sensor terminal B and power supply
End Of Sie
WM: INTAKE AIR TEMPERATURE SENSOR
01-40A–26
CONTROL SYSTEM [L3]
INTAKE AIR TEMPERATURE (IAT) SENSOR INSPECTION[L3]
id0140a7802200
Note
1. Disconnect MAF/IAT sensor.

2. Measure the resistance between the MAF/IAT
sensor terminals D and E using an ohmmeter. 01
• If not as specified, replace the MAF/IAT
sensor.
• If the MAF/IAT sensor is okay, but the IAT PID
are out of specification, perform the “Circuit E D C B A
Open/Short Inspection”.
Specification
Ambient temperature (°C {°F}) Resistance (kilohm)
–20 {–4} 13.6—18.4
20 {68} 2.21—2.69
60 {140} 0.493—0.667 atraaw00001322
MAF/IAT SENSOR
(HARNESS SIDE CONNECTOR)
E D C B A
atraaw00001323
PCM
atraaw00001324

Open circuit
— MAF/IAT sensor terminal D and PCM terminal 1AH
— MAF/IAT sensor terminal E and PCM terminal 1AE
Short circuit
— MAF/IAT sensor terminal E and power supply
— MAF/IAT sensor terminal D and power supply
— MAF/IAT sensor terminal D and body ground
End Of Sie
WM: MANIFOLD ABSOLUTE PRESSURE SENSOR
01-40A–27
CONTROL SYSTEM [L3]
MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR REMOVAL/INSTALLATION[L3]
id0140a7804300
2. Disconnect the MAP sensor connector.
3. Remove the MAP sensor installation screw.
4. Remove the MAP sensor from the intake
manifold.
Tightening torque
2.7—3.7 N·m {28—37 kgf·cm, 24—32 in·lbf}
End Of Sie
VARIABLE INTAKE AIR
MAP SENSOR SHUTTE VALVE ACTUATOR
atraaw00001855
MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR INSPECTION[L3]

id0140a7800900
Note
• The following vacuum values are indicated by relative pressure from the MAP sensor.
1. Connect the SST (IDS/PDS) to the DLC-2.

2. Turn the ignition switch to ON (Engine OFF).
3. Select MAP PID on the SST (IDS/PDS).
4. Verify that the MAP PID (pressure) and the
barometric pressure are practically equal.
• If not as verified, perform the “Circuit Open/
Short Inspection”.
— If there is no open or short circuit, replace
the MAP sensor.
• If as verified, go to next step.
DLC-2
aesffw00000044
MAP SENSOR
D C B A
atraaw00001325
PCM
atraaw00001326
01-40A–28
CONTROL SYSTEM [L3]
2. Inspect the following wiring harness for open or short. (Continuity check)
Open circuit
— MAP sensor terminal A and PCM terminal 2AX
— MAP sensor terminal D and PCM terminal 2AL
— MAP sensor terminal C and PCM terminal 2AT
Short circuit
01
— MAP sensor terminal C and power supply.
— MAP sensor terminal C and body ground.
— MAP sensor terminal D and power supply.
— MAP sensor terminal D and body ground
End Of Sie
THROTTLE POSITION (TP) SENSOR INSPECTION[L3]
WM: THROTTLE POSITION SENSOR
id0140a7802700
Note
Voltage Inspection
1. Verify that no DTC related to APP sensor has been detected.
• If any DTCs related to APP sensor have been detected, perform the DTC inspection.
2. Start the engine and warm it up (ECT: more than 80°C {176 °F}).
3. Turn the ignition switch to ON position (Engine off).
4. Verify that the PCM terminal 2M and 2I change smoothly while throttle valve is gradually opened.
• If as verified, go to next step.
• If not as verified, perform the “Circuit Open/Short Inspection”.
— If there is no open or short circuit, replace the throttle body.
5. Verify that the PCM terminal 2M and 2I voltages are as shown in the following table.
PCM
atraaw00001327
• If voltage is not as following table, perform the “Circuit Open/Short Inspection”.

01-40A–29
CONTROL SYSTEM [L3]
TP sensor output voltage THE CHARACTERISTICS OF

TP SENSOR (REFERENCE)
PCM terminal PCM terminal
Condition 2M 2I
(TP sensor No.1) (TP sensor No.2) HIGH TP SENSOR No.1
CTP 0.4—0.6 V 4.4—4.6 V
WOT 4.4—4.7 V 0.3—0.6 V
OUTPUT TP SENSOR No.2

VOLTAGE
LOW
THROTTLE
SMALL LARGE
OPENING ANGLE
atraaw00001328
TP SENSOR
F E D C B A
atraaw00001329
PCM
atraaw00001327

2. Inspect the following wiring harnesses for open or short circuit. (Continuity check)
Open circuit
— Throttle body terminal A and PCM terminal 2M
— Throttle body terminal B and PCM terminal 2K
— Throttle body terminal C and PCM terminal 2I
— Throttle body terminal D and PCM terminal 2O
Short circuit
— Throttle body terminal A and power supply
— Throttle body terminal A and body ground
— Throttle body terminal B and power supply
— Throttle body terminal B and body ground
— Throttle body terminal C and power supply
— Throttle body terminal C and body ground
— Throttle body terminal D and power supply
01-40A–30
CONTROL SYSTEM [L3]
End Of Sie
ACCELERATOR PEDAL POSITION (APP) SENSOR INSPECTION[L3]

WM: ACCELERATOR PEDAL POSITION SENSOR
id0140a7803200
Note
Voltage Inspection
1. Turn the ignition key to ON position (Engine OFF).
2. Verify that the PCM terminal 1Y and 1AG change smoothly while throttle valve is gradually opened.
• If as verified, go to next step. 01
• If not as verified, perform the “Circuit Open/Short Inspection”.
3. Verify that the PCM terminal 1Y and 1AG voltages are as shown in the following table.
PCM
atraaw00001330
• If voltage is not as following table, perform the “Circuit Open/Short Inspection”.

— If there is no open or short circuit, replace accelerator pedal. (See 01-13A-10 ACCELERATOR PEDAL
APP sensor output voltage

PCM terminal 1Y PCM terminal 1AG
Condition
(APP sensor No.1) (APP sensor No.2)
Accelerator
Approx. 1.6 V Approx. 1.03 V
pedal released
Accelerator
Approx. 3.9 V Approx. 3.35 V
pedal depressed
01-40A–31
CONTROL SYSTEM [L3]
APP SENSOR
F E D C B A
aesffw00000503
PCM
atraaw00001330

2. Inspect the following wiring harnesses for open or short circuit. (Continuity check)
Open circuit
— APP sensor terminal A and PCM terminal 1AK
— APP sensor terminal B and PCM terminal 1AA
— APP sensor terminal C and PCM terminal 1AG
— APP sensor terminal D and PCM terminal 1AW
— APP sensor terminal E and PCM terminal 1I
— APP sensor terminal F and PCM terminal 1Y
Short circuit
— APP sensor terminal A and power supply
— APP sensor terminal A and body ground
— APP sensor terminal B and power supply
— APP sensor terminal C and power supply
— APP sensor terminal C and body ground
— APP sensor terminal D and power supply
— APP sensor terminal D and body ground
— APP sensor terminal E and power supply
— APP sensor terminal F and power supply
— APP sensor terminal F and body ground
End Of Sie
WM: HEATED OXYGEN SENSOR
01-40A–32
CONTROL SYSTEM [L3]
HEATED OXYGEN SENSOR (HO2S) INSPECTION[L3]
id0140a7802300
Note
• Before performing the following inspection, make sure to follow the troubleshooting flowchart. (See 01-
03A-6 FOREWORD[L3].)
Front HO2S Current Inspection

1. Warm up the engine to normal operating temperature.
2. Using the IDS/PDS, monitor the following: 01
— Vehicle speed (PID: VSS)
— Engine speed (PID: RPM)
— Front HO2S current (PID: O2S11)
3. Drive the vehicle and decelerate the engine speed by releasing the accelerator pedal fully when the engine
speed is 3,000 rpm or more.
4. Verify that the front HO2S current (PID: O2S11) is 0.25 mA or more while decelerating as shown in the figure.
VSS
0 KPH
3,000 RPM
2,000 RPM
RPM
1,000 RPM
0 RPM
0.25 mA
0.25 mA OR MORE
O2S11
0 mA
atraaw00001332
• If not within the specification, inspect the HO2S for an open or short circuit. (See 01-40A-34 Front HO2S
circuit open/short inspection (sensor).) Then if there is no malfunction in the wiring harness, replace the
front HO2S.
Front HO2S heater resistance inspection

1. Disconnect the front HO2S connector.
2. Measure the resistance between front HO2S
terminals A and B.
• If not within the specification, replace the front
HO2S.
E C A
Front HO2S heater resistance F D B
1—10 ohms
atraaw00001333
01-40A–33
CONTROL SYSTEM [L3]
Front HO2S circuit open/short inspection (sensor)
2. Disconnect the front HO2S connector.
open or short circuit. (Continuity inspection)
FRONT HO2S
E C A
F D B
atraaw00001334
MAIN FUSE BLOCK

(FUEL PUMP RELAY)
B
A E
FRONT
D
atraaw00000831
PCM
atraaw00001336
Open circuit
• If there is no continuity in the following wiring harnesses, there is an open circuit. Repair or replace the wiring
harness.
— Front HO2S terminal B and PCM terminal 2AD
— Front HO2S terminal D and PCM terminal 2AC
— Front HO2S terminal F and PCM terminal 2Z
Short circuit
• If there is continuity in the following wiring harnesses, there is a short circuit. Repair or replace the wiring
harness.
— Front HO2S terminal B and body ground
— Front HO2S terminal B and power supply
— Front HO2S terminal D and body ground
— Front HO2S terminal D and power supply
— Front HO2S terminal F and body ground
— Front HO2S terminal F and power supply
01-40A–34
CONTROL SYSTEM [L3]
Rear HO2S voltage inspection
1. Warm up the engine to normal operating temperature.
2. Using the IDS/PDS, monitor the following:
— Rear HO2S voltage (PID: O2S12)
4. Verify that the rear HO2S outputs a voltage of 0.6 V or more, one time or more, then verify that the rear HO2S
voltage (PID: O2S12) is 0.3 V or less while decelerating as shown in the figure.
01
VSS
0 KPH
3000 RPM
2000 RPM
RPM
1000 RPM
0 RPM
1V
O2S12 0.5V
0.3V OR LESS
0V
atraaw00001337
• If not within the specification, inspect the HO2S for an open or short circuit. (See 01-40A-36 Rear HO2S
circuit open/short inspection (sensor).) Then if there is no malfunction in the wiring harness, replace the
rear HO2S.
01-40A–35
CONTROL SYSTEM [L3]
Rear HO2S circuit open/short inspection (sensor)
REAR HO2S
C A
D B
aesffw00000504
PCM
atraaw00001336

2. Disconnect the rear HO2S connector.
3. Inspect the following wiring harnesses for an open or short circuit. (Continuity inspection)
Open circuit
— Rear HO2S terminal A and PCM terminal 2AH
— Rear HO2S terminal B and PCM terminal 2AA
Short circuit
— Rear HO2S terminal A and body ground
— Rear HO2S terminal A and power supply
— Rear HO2S terminal B and power supply
Rear HO2S heater resistance inspection

2. Measure the rear HO2S resistance between
terminals C and D.
HO2S. C A
Rear HO2S heater resistance D B

2—50 ohms
aesffw00000505
01-40A–36
CONTROL SYSTEM [L3]
Rear HO2S circuit open/short inspection (heater)
REAR HO2S
C A
D B
01
aesffw00000504
PCM
atraaw00001336

3. Inspect the following wiring harnesses for an open or short circuit. (Continuity inspection)
Open circuit
— Rear HO2S terminal C and ignition switch
— Rear HO2S terminal D and PCM terminal 2C
Short circuit
• If there is no continuity, there is a short circuit. Repair or replace the wiring harness.
Rear
— Rear HO2S terminal C and body ground
— Rear HO2S terminal D and power supply
— Rear HO2S terminal D and body ground
End Of Sie
CRANKSHAFT POSITION (CKP) SENSOR REMOVAL/INSTALLATION[L3]
WM: CRANKSHAFT POSITION PLATE
id0140a7800600
Removal
1. Perform the following procedure to making the working space.
(1) Remove the Front wheel (RH).
(2) Remove the splash shield.
2. Disconnect the CKP sensor connector.
3. Remove the installation bolts to remove the CKP sensor.
Installation
Caution
• When foreign material such as an iron chip is on the CKP sensor, it can cause abnormal output
from the sensor because of flux turbulence and adversely affect the engine control. Be sure there
is no foreign material on the CKP sensor when replacing.
1. Perform the following procedure so that piston No.1 is at the top dead center.
(1) Remove the front drive shaft (RH). (See 03-13-7 FRONT DRIVE SHAFT REMOVAL/INSTALLATION.)
01-40A–37
CONTROL SYSTEM [L3]
(2) Remove the cylinder block lower blind plug
and install the SST.
(3) Turn the crankshaft pulley to the clockwise
until it stops.
2. Install the CKP sensor to the CKP sensor
installer.
303-507
(49 JE01 061)
atraaw00003115
3. Fit the forked part of the CKP sensor installer with

the fifth tooth (counting counterclockwise from the
empty space A as shown in the figure) of the EMPTY
pulse wheel. SPACE B
4. Install the CKP sensor fitting bolts. EMPTY
SPACE A
Tightening torque MARK LINE AT
5.5—7.5 N·m {56—76 kgf·cm, 4.1—5.5 ft·lbf} CENTER OF
5TH TOOTH
5. Remove the CKP sensor installer EMPTY
SPACE C
6. Remove the SST then install the cylinder block
lower blind plug.
Tightening torque
20 N·m {2.0 kgf·m, 15 ft·lbf}
CKP SENSOR
7. Install the front drive shaft (RH). (See 03-13-7
FRONT DRIVE SHAFT REMOVAL/ atraaw00003116
INSTALLATION.)
End Of Sie
CRANKSHAFT POSITION (CKP) SENSOR INSPECTION[L3]
id0140a7800500
Note
• Perform the following inspection according to the DATA MONITOR function (indicated by monitor item from
here onwards).
Air Gap Inspection

1. Verify that the CKP sensor is securely installed.
2. Using a thickness gauge, measure the air gap between the plate projections at the back of crankshaft pulley
and the CKP sensor.
• If not within the specification, inspect the plate projections for cracks or bending.
— If there is any malfunction, replace the plate.
— If the monitor item condition/specification (reference) is not within the specification, even though there is
no malfunction, carry out the “Circuit Open/Short Inspection”.
Air gap
0.5—1.4 mm {0.02—0.05 in}
Visual inspection
2. Remove the CKP sensor. (See 01-40A-37 CRANKSHAFT POSITION (CKP) SENSOR REMOVAL/
INSTALLATION[L3].)
3. Verify that there are no metal shavings on the sensor.
• If the monitor item condition/specification (reference) is without the specification even though there is no
malfunction, carry out the “Circuit Open/Short Inspection”.
Voltage Inspection
1. Idle the engine.
Caution
• Water penetrating the connector will cause sensor malfunction. To prevent this, be careful not to
damage the wiring harnesses or the waterproof connector so as to cause water penetration.
01-40A–38
CONTROL SYSTEM [L3]
2. Measure the output voltage using a oscilloscope.
• If not within the specification, replace the CKP
sensor. CKP SENSOR
• If the monitor item condition/specification WIRING HARNESS SIDE CONNECTOR
(reference) is without the specification, even
though the voltage is within the specification, C B A
carry out the “Circuit Open/Short Inspection”.
Voltage
Terminal Voltage (V) Condition
01
A B+ Under any condition
4.8 or more High output* atraaw00001339
B
0.8 or less Low output*
C 0 Under any condition
*
: Output voltage varies with crankshaft rotation.
CKP SENSOR
C B A
atraaw00001340
PCM
atraaw00001342
1. Inspect the following wiring harnesses for an open or short circuit. (Continuity check)
Open circuit
— CKP sensor terminal A and body ground
— CKP sensor terminal B and PCM terminal 2U
— CKP sensor terminal C and PCM terminal 2T
Short circuit
— CKP sensor terminal A and power supply
— CKP sensor terminal B and power supply
— CKP sensor terminal B and body ground
— CKP sensor terminal C and body ground
End Of Sie
WM: CAMSHAFT POSITION SENSOR
01-40A–39
CONTROL SYSTEM [L3]
CAMSHAFT POSITION (CMP) SENSOR REMOVAL/INSTALLATION[L3]
id0140a7801500
3. Remove the plug hole cover.
Caution
• When replacing the CMP sensor, make sure there is no foreign material on it such as metal
shavings. If it is installed with foreign material, the sensor output signal will malfunction resulting
from fluctuation in magnetic flux and cause a deterioration in engine control.
4. Disconnect the CMP sensor connector.

5. Remove the CMP sensor installation bolt.
6. Remove the CMP sensor from the cylinder head
cover.
CMP SENSOR
Tightening torque 5.5—7.5 N·m
{57—76 kgf·cm,
5.5—7.5 N·m {56—76 kgf·cm, 49—66 in·lbf} 49—66 in·lbf}
End Of Sie
atraaw00003125
CAMSHAFT POSITION (CMP) SENSOR INSPECTION[L3]

id0140a7801400
Note
• Perform the following inspection according to the DATA MONITOR function (indicated by monitor item from
here onwards).
Visual Inspection
2. Remove the CMP sensor. (See 01-40A-40 CAMSHAFT POSITION (CMP) SENSOR REMOVAL/
INSTALLATION[L3].)
3. Verify that there are no metal shavings on the sensor.
• If the monitor item condition/specification (reference) is not within the specification even though there is no
malfunction, carry out the “Circuit Open/Short Inspection”.
Voltage inspection
1. Idle the engine.
Caution
2. Measure the output voltage using a oscilloscope.

• If not within the specification, replace the CMP SENSOR
CMP sensor. WIRING HARNESS SIDE CONNECTOR
• If the monitor item condition/specification
even though the voltage is within the C B A
specification, carry out the “Circuit Open/
Short Inspection”.
Voltage
Terminal Voltage (V) Condition
A B+ Under any condition atraaw00001343
4.8 or more High output*
B
0.8 or less Low output*
C 0 Under any condition
* : Output voltage varies with camshaft rotation.
01-40A–40
CONTROL SYSTEM [L3]
CMP SENSOR
C B A
01
atraaw00001343
PCM
atraaw00001345
1. Inspect the following wiring harnesses for an open or short circuit. (Continuity check)
Open circuit
— CMP sensor terminal A and body ground
— CMP sensor terminal B and PCM terminal 2V
— CMP sensor terminal C and PCM terminal 2X
Short circuit
— CMP sensor terminal A and power supply
— CMP sensor terminal B and power supply
— CMP sensor terminal B and body ground
— CMP sensor terminal C and power supply
End Of Sie
KNOCK SENSOR (KS) REMOVAL/INSTALLATION[L3]
WM: KNOCK SENSOR
id0140a7802900
2. Remove the intake manifold. (See 01-13A-5 INTAKE-AIR SYSTEM REMOVAL/INSTALLATION[L3].)
3. Remove the KS attachment bolt to remove the KS
KS.
Tightening torque
16.2—23.8 N·m
{1.7—2.4 kgf·m, 12.0—17.5 ft·lbf}
End Of Sie
atraaw00002227
01-40A–41
CONTROL SYSTEM [L3]
KNOCK SENSOR (KS) INSPECTION[L3]
id0140a7802800
Note
• Perform the following test only when directed.
1. Turn the ignition switch to LOCK.
2. Disconnect the KS connector.
3. Measure the resistance between the KS terminals A and B using an ohmmeter.
• If not as specified, replace the KS.
• If the KS is okay, but PID value is out of specification, perform the “Circuit Open/Short Inspection”.
Specification
Approx. 4.87 megohms
KNOCK SENSOR
A B
aesffw00000506
PCM
atraaw00001347

Open circuit
— KS terminal A and PCM terminal 2Q
— KS terminal B and PCM terminal 2R
Short circuit
— KS terminal A and power supply
— KS terminal A and body ground
— KS terminal B and power supply
— KS terminal B and body ground
End Of Sie
01-40A–42
CONTROL SYSTEM [AJ (3.0L Duratec)]
01-40B CONTROL SYSTEM [AJ (3.0L Duratec)]

CONTROL SYSTEM COMPONENT THROTTLE POSITION (TP) SENSOR
LOCATION INDEX INSPECTION[AJ (3.0L Duratec)] . . . . . 01-40B–22
[AJ (3.0L Duratec)] . . . . . . . . . . . . . . . . 01-40B–2 CRANKSHAFT POSITION (CKP)
CONTROL SYSTEM WIRING DIAGRAM SENSOR REMOVAL/INSTALLATION
PCM REMOVAL/INSTALLATION CRANKSHAFT POSITION (CKP)
[AJ (3.0L Duratec)] . . . . . . . . . . . . . . . . 01-40B–6 SENSOR INSPECTION 01
PCM INSPECTION [AJ (3.0L Duratec)] . . . . . . . . . . . . . . . . 01-40B–23
[AJ (3.0L Duratec)] . . . . . . . . . . . . . . . . 01-40B–6 CAMSHAFT POSITION (CMP) SENSOR
PCM CONFIGURATION REMOVAL/INSTALLATION
POWER STEERING PRESSURE (PSP) CAMSHAFT POSITION (CMP) SENSOR
SWITCH REMOVAL/INSTALLATION INSPECTION[AJ (3.0L Duratec)] . . . . . 01-40B–25
[AJ (3.0L Duratec)] . . . . . . . . . . . . . . . . 01-40B–15 FRONT HEATED OXYGEN SENSOR
POWER STEERING PRESSURE (PSP) (HO2S) REMOVAL/INSTALLATION
SWITCH INSPECTION [AJ (3.0L Duratec)] . . . . . . . . . . . . . . . . 01-40B–26
[AJ (3.0L Duratec)] . . . . . . . . . . . . . . . . 01-40B–16 FRONT HEATED OXYGEN SENSOR
ENGINE COOLANT TEMPERATURE (ECT) (HO2S) INSPECTION
SENSOR REMOVAL/INSTALLATION [AJ (3.0L Duratec)] . . . . . . . . . . . . . . . . 01-40B–27
[AJ (3.0L Duratec)] . . . . . . . . . . . . . . . . 01-40B–17 REAR HEATED OXYGEN SENSOR
ENGINE COOLANT TEMPERATURE (ECT) (HO2S) REMOVAL/INSTALLATION
SENSOR INSPECTION [AJ (3.0L Duratec)] . . . . . . . . . . . . . . . . 01-40B–30
[AJ (3.0L Duratec)] . . . . . . . . . . . . . . . . 01-40B–17 REAR HEATED OXYGEN SENSOR
MASS AIR FLOW (MAF) SENSOR (HO2S) INSPECTION
[AJ (3.0L Duratec)] . . . . . . . . . . . . . . . . 01-40B–18 DIFFERENTIAL PRESSURE
MASS AIR FLOW (MAF) SENSOR FEEDBACK (D.P.F.) EGR SENSOR
INSPECTION[AJ (3.0L Duratec)] . . . . . 01-40B–19 REMOVAL/INSTALLATION
INTAKE AIR TEMPERATURE (IAT) [AJ (3.0L Duratec)] . . . . . . . . . . . . . . . . 01-40B–33
SENSOR INSPECTION DIFFERENTIAL PRESSURE
[AJ (3.0L Duratec)] . . . . . . . . . . . . . . . . 01-40B–20 FEEDBACK (D.P.F.) EGR SENSOR
INSPECTION[AJ (3.0L Duratec)] . . . . . 01-40B–33
End of Toc
WM: ENGINE CONTROL SYSTEM
01-40B–1
CONTROL SYSTEM COMPONENT LOCATION INDEX[AJ (3.0L Duratec)]
id0140a1800200
8
9
2
4
atraaw00000143
1 PCM 2 MAF/IAT sensor

(See 01-40B-6 PCM REMOVAL/INSTALLATION[AJ (See 01-40B-18 MASS AIR FLOW (MAF) SENSOR
(3.0L Duratec)].) REMOVAL/INSTALLATION[AJ (3.0L Duratec)].)
(See 01-40B-6 PCM INSPECTION[AJ (3.0L (See 01-40B-19 MASS AIR FLOW (MAF) SENSOR
Duratec)].) INSPECTION[AJ (3.0L Duratec)].)
(See 01-40B-15 PCM CONFIGURATION[AJ (3.0L (See 01-40B-20 INTAKE AIR TEMPERATURE (IAT)
Duratec)].) SENSOR INSPECTION[AJ (3.0L Duratec)].)
3 TP sensor
(See 01-40B-22 THROTTLE POSITION (TP)
SENSOR INSPECTION[AJ (3.0L Duratec)].)
01-40B–2
4 ECT sensor 8 HO2S
(See 01-40B-17 ENGINE COOLANT (See 01-40B-26 FRONT HEATED OXYGEN
TEMPERATURE (ECT) SENSOR REMOVAL/ SENSOR (HO2S) REMOVAL/INSTALLATION[AJ
INSTALLATION[AJ (3.0L Duratec)].) (3.0L Duratec)].)
(See 01-40B-17 ENGINE COOLANT (See 01-40B-27 FRONT HEATED OXYGEN
TEMPERATURE (ECT) SENSOR INSPECTION[AJ SENSOR (HO2S) INSPECTION[AJ (3.0L
(3.0L Duratec)].) Duratec)].)
5 CMP sensor (See 01-40B-30 REAR HEATED OXYGEN
(See 01-40B-24 CAMSHAFT POSITION (CMP) SENSOR (HO2S) REMOVAL/INSTALLATION[AJ
SENSOR REMOVAL/INSTALLATION[AJ (3.0L (3.0L Duratec)].) 01
Duratec)].) (See 01-40B-31 REAR HEATED OXYGEN
(See 01-40B-25 CAMSHAFT POSITION (CMP) SENSOR (HO2S) INSPECTION[AJ (3.0L
SENSOR INSPECTION[AJ (3.0L Duratec)].) Duratec)].)
6 CKP sensor 9 D.P.F. EGR sensor
(See 01-40B-23 CRANKSHAFT POSITION (CKP) (See 01-40B-33 DIFFERENTIAL PRESSURE
SENSOR REMOVAL/INSTALLATION[AJ (3.0L FEEDBACK (D.P.F.) EGR SENSOR REMOVAL/
Duratec)].) INSTALLATION[AJ (3.0L Duratec)].)
(See 01-40B-23 CRANKSHAFT POSITION (CKP) (See 01-40B-33 DIFFERENTIAL PRESSURE
SENSOR INSPECTION[AJ (3.0L Duratec)].) FEEDBACK (D.P.F.) EGR SENSOR
7 PSP switch
(See 01-40B-15 POWER STEERING PRESSURE
(PSP) SWITCH REMOVAL/INSTALLATION[AJ (3.0L
Duratec)].)
(See 01-40B-16 POWER STEERING PRESSURE
(PSP) SWITCH INSPECTION[AJ (3.0L Duratec)].)
End Of Sie
01-40B–3
CONTROL SYSTEM WIRING DIAGRAM[AJ (3.0L Duratec)]
id0140a1800400
PCM
24 51 76 103 3 55 18 17 44 15 16 13 71 97 25 8040 28 46 69 41 86 60 87 35 61 93 94 95 96 88 36 39 38
a
b
A/C RELAY
PRESSURE SIGNAL
SWITCH (LOW, HIGH PRESSURE)
FAN RELAY NO.1, NO.3
FAN RELAY NO.2
TO STARTER RELAY
c
COIL ANTENNA
COIL ANTENNA
REFRIGERANT
d
TO
INSTRUMENT
CLUSTER FRONT HO2S MAF/IAT
(RH) SENSOR
DLC-2
e
f
MAIN RELAY FUEL PUMP g

RELAY ECT SENSOR
TO IGNITION
SWITCH FRONT HO2S
(LH)
STARTER
FUEL PUMP
RELAY
STOP SWITCH
TO STARTER
TO PCM #44
h
P REAR HO2S i
(RH) j
TO
INSTRUMENT TP SENSOR
IGNITION SWITCH
CLUSTER
T P OFFACC ON ST
B k
FUEL PUMP UNIT l
ACC
IG1 m
ST REAR HO2S
D.P.F. EGR SENSOR
IG1 (LH)
n
ACC STARTER
STA RELAY
A/C EQUIPPED
ONLY
COOLING FAN
COOLING FAN
COOLING FAN
A/C
P TR
RELAY NO.3
RELAY NO.1
RELAY NO.2
BLOWER A/C
SWITCH FAN MOTOR SWITCH RELAY
SWITCH (LOW PRESSURE)
M
(MEDIUM PRESSURE)
PRESSURE SWITCH
OIL PRESSURE
H
TO PCM#69
PRESSURE SWITCH
(HIGH PRESSURE)
M
REFRIGERANT
SWITCH
REFRIGERANT
L M M
BATTERY
3 21
TO PCM#86
M 4 0
OFF TO PCM#46 TO PCM#28
M
STARTER GENERATOR C
FAN SWITCH MAGNETIC CLUTCH
TO PCM#41
aesffw00000429
01-40B–4
PCM
89 65 9190 31 83 47 56 99 73100 74 101 75 85 21 22 26 52 78 1 27 53 84 68 64 59 6 11 20 54 81 37 92 29
a
b
O/D OFF SWITCH

TO
PSP SWITCH
CRUISE
c
ACTUATOR 01
CMP SENSOR
CKP SENSOR
TSS
SENSOR
d OSS
SENSOR
BRAKE LIGHT
e
f
BRAKE SWITCH
g NO.1
IAC
ATX CONNECTOR
SOLENOID
VALVE TR SWITCH
NO.2
NO.6
FUEL INJECTOR
NO.3 NO.5
EGR
NO.3
IGNITION COIL
CONTROL
h VALVE NO.4
NO.4
i NO.2
j IGNITION COIL
NO.5 NO.1 CONDENSER

k PURGE
l SOLENOID
m VALVE
NO.6
CONDENSER
n
aesffw00000430
End Of Sie
WM: PCM
01-40B–5
PCM REMOVAL/INSTALLATION[AJ (3.0L Duratec)]
id0140a1802400
Caution
• Before PCM removal, the PCM configuration information must be uploaded to the diagnostic tool.
This information needs to be downloaded into the new PCM once installed.
(See 01-40B-15 PCM CONFIGURATION[AJ (3.0L Duratec)].)

2. Loosen the PCM connector bolt and remove the PCM COVER
PCM connector.
3. Remove the PCM cover nuts and the PCM cover.
atraaw00000146
4. Remove the PCM.
Caution
• Download the PCM configuration
information from the diagnostic tool to
the new PCM once installed.
(See 01-40B-15 PCM
CONFIGURATION[AJ (3.0L Duratec)].)
5. Install in the reverse order of removal. PCM
PCM installation bolts tightening torque

atraaw00000147
3.0—5.4 N·m {31—55 kgf·cm, 27—47 in·lbf}
PCM cover installation bolts tightening torque
4.0—5.6 N·m {41—57 kgf·cm, 36—49 in·lbf}
End Of Sie
PCM INSPECTION[AJ (3.0L Duratec)]
id0140a1802500
Note
• The PCM terminal voltage can vary with the conditions when measuring, and deterioration over time on
the vehicle, causing false diagnosis. Therefore a comprehensive determination of where malfunctions are
occurring is required for input/output system, or PCM.

2. Remove the PCM.
3. Connect the powertrain control module (PCM) electrical connector.
5. Connect the negative (–) lead of the circuit tester to the body ground.
6. Measure the voltage at each PCM terminal using the (digital) circuit tester.
• If the output voltage is unusual despite normal input voltage, inspect the related systems. If they are
normal, replace the PCM.
01-40B–6
Terminal Voltage Table (Reference)
PCM WIRING HARNESS-SIDE
CONNECTOR
26 25 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
52 51 50 49 48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27
78 77 76 75 74 73 72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53
104103102 101100 99 98 97 96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79
01
atraaw00001595
Terminal Signal name Connected to Measurement condition Voltage (V) Inspection item
• Ignition coil
Ignition coil (See 01-40B-11 Inspection Using An Oscilloscope
1 Ignition coil • Related wiring
control (Reference).)
harness
2 — — — — —
• Related wiring
3 Ground Ground Under any condition 1.0 or less
harness
4 — — — — —
5 — — — — —
Solenoid valve operating B+ • Shift solenoid A
Shift solenoid A
6 Shift solenoid A • Related wiring
control Solenoid valve not operating 1.0 or less harness
7 — — — — —
8 — — — — —
9 — — — — —
10 — — — — —
Solenoid valve operating B+ • Shift solenoid B
Shift solenoid B
11 Shift solenoid B • Related wiring
control Solenoid valve not operating 1.0 or less harness
12 — — — — —
13 — — — — —
14 — — — — —
As this terminal is for communication, terminal
• Related wiring
15 BUS- PDS/IDS voltage inspection is not suitable for
harness
determination.Inspect with DTC inspection.
As this terminal is for communication, terminal
• Related wiring
16 BUS+ PDS/IDS voltage inspection is not suitable for
harness
determination.Inspect with DTC inspection.
As this terminal is for communication, terminal • Coil antenna
17 Key ID Coil antenna voltage inspection is not suitable for determination. • Related wiring
Inspect with DTC inspection. harness
As this terminal is for communication, terminal • Coil antenna
18 Key ID Coil antenna voltage inspection is not suitable for determination. • Related wiring
Inspect with DTC inspection. harness
19 — — — — —
Solenoid valve operating B+ • 3-2 timing/coast
3-2 timing/coast 3-2 timing/ clutch solenoid
20 clutch solenoid coast clutch valve
valve control solenoid valve Solenoid valve not operating 1.0 or less • Related wiring
harness
• CKP sensor
Engine rotation (See 01-40B-11 Inspection Using An Oscilloscope
21 CKP sensor • Related wiring
(+) (Reference).)
harness
• CKP sensor
Engine rotation (See 01-40B-11 Inspection Using An Oscilloscope
22 CKP sensor • Related wiring
(–) (Reference).)
harness
23 — — — — —
• Related wiring
harness
01-40B–7
• Related wiring
harness
• Ignition coil
harness
• Ignition coil
harness
Cooling fan on 1.0 or less • Cooling fan relay
Low speed control Cooling fan No.2
28 While idling
fan relay control relay No.2 Cooling fan off B+ • Related wiring
harness
While O/D OFF
switch is pressed
B+ • O/D OFF switch
O/D OFF Ignition switch at inspection
29 O/D OFF Except when O/D
switch ON • Related wiring
OFF switch is 1.0 or less harness
pressed
30 — — — — —
Steering wheel
neutral
B+ • PSP switch
31 PSP PSP switch While idling • Related wiring
While steering harness
1.0 or less
wheel is turned
32 — — — — —
33 — — — — —
34 — — — — —
Alternates • Rear HO2S (RH)
Rear HO2S
35 Rear HO2S (RH) Idle after warm-up between 0 • Related wiring
(RH)
and 1.0 harness
• MAF sensor
Input device
36 MAF sensor Under any condition 1.0 or less • Related wiring
ground
harness
At ATF
temperature 20 34
• TFT sensor
Ignition switch at °C {68 °F}
37 ATF temperature TFT sensor • Related wiring
ON At ATF harness
temperature 130 0.20.7
°C {266 °F}
ECT is 20 °C {68
Approx. 3.1
°F}
• ECT sensor
Ignition switch at ECT is 60 °C {140
38 ECT ECT sensor Approx. 1.4 • Related wiring
ON °F}
harness
ECT is 80 °C {176
Approx. 0.9
°F}
At IAT 20 °C {68
°F}
Approx. 2.5 • IAT sensor
Intake air Ignition switch at
39 IAT sensor • Related wiring
temperature ON At IAT 30 °C {86
Approx. 1.8 harness
°F}
Fuel pump Ignition switch at ON 1.0 or less • Fuel pump relay
Fuel pump
40 operation Cranking • Related wiring
relay B+
detection While idling harness
A/C on 1.0 or less • A/C switch
Refrigerant
• Refrigerant
pressure switch
pressure switch
41 A/C signal (low, high While idling
A/C off B+ (low, high pressure)
pressure), A/C
• Related wiring
switch
harness
42 — — — — —
43 — — — — —
P or N position B+ • Starter relay
44 Starter cut control Starter relay • Related wiring
Except above 1.0 or less harness
45 — — — — —
01-40B–8
Cooling fan on 1.0 or less • Cooling fan relay
Cooling fan
High speed No.1, Cooling fan
relay No.1,
46 control fan relay While idling relay No.3
Cooling fan Cooling fan off B+
control • Related wiring
relay No.3
harness
• EGR control valve
EGR control valve EGR control
47 While idling B+ • Related wiring
control valve
48 — — — —
harness
—
01
49 — — — — —
50 — — — — —
• Related wiring
harness
• Ignition coil
harness
• Ignition coil
harness
Solenoid valve operating B+ • Torque converter
Torque
clutch solenoid
Torque converter converter
54 valve
clutch control clutch solenoid Solenoid valve not operating 1.0 or less • Related wiring
valve
harness
• Battery
Backup power • Main fuse
55 Battery Under any condition B+
supply • Related wiring
harness
• Purge solenoid
Evaporative Purge solenoid (See 01-40B-11 Inspection Using An Oscilloscope valve
56
purge control valve (Reference).) • Related wiring
harness
57 — — — — —
58 — — — — —
• TSS sensor
(See 01-40B-11 Inspection Using An Oscilloscope
59 Turbine speed TSS sensor • Related wiring
(Reference).)
harness
• Front HO2S (RH)
Front HO2S (See 01-40B-11 Inspection Using An Oscilloscope
60 Front HO2S (RH) • Related wiring
(RH) (Reference).)
harness
Alternates • Rear HO2S (LH)
Rear HO2S
61 Rear HO2S (LH) Idle after warm-up between 0 • Related wiring
(LH)
and 1.0 harness
62 — — — — —
63 — — — — —
P position Approx. 4.4
R position Approx. 3.6
• TR switch
Ignition switch at N position Approx. 2.9
64 TR TR switch • Related wiring
ON D range Approx. 2.1 harness
2 Range Approx. 1.4
1 Range Approx. 0.7
• D.P.F. EGR sensor
D.P.F. EGR
65 EGR flow While idling after warm-up Approx. 1 • Related wiring
sensor
harness
66 — — — — —
67 — — — — —
68 — — — — —
• A/C relay
69 A/C control A/C relay A/C on 1.0 or less • Related wiring
harness
70 — — — — —
01-40B–9
Ignition switch at ON B+ • Main relay
71 Power supply Main relay • Related wiring
Ignition switch is off. 1.0 or less harness
72 — — — — —
• Fuel injector
Fuel injector No.5 Fuel injector (See 01-40B-11 Inspection Using An Oscilloscope
73 • Related wiring
control No.5 (Reference).)
harness
• Fuel injector
harness
• Fuel injector
harness
• Related wiring
harness
77 — — — — —
• Ignition coil
harness
79 — — — — —
Ignition switch at ON B+ • Fuel pump relay
Fuel pump
80 Fuel pump control Cranking • Related wiring
relay 1.0 or less
While idling harness
Electronic • Electronic pressure
Electronic
pressure (See 01-40B-11 Inspection Using An Oscilloscope control solenoid
81 pressure control
control (Reference).) • Related wiring
solenoid control
solenoid harness
82 — — — — —
• IAC solenoid valve
IAC solenoid (See 01-40B-11 Inspection Using An Oscilloscope
83 IAC control • Related wiring
valve (Reference).)
harness
• Output shaft speed
Output shaft Output shaft (See 01-40B-11 Inspection Using An Oscilloscope sensor
84
speed speed sensor (Reference).) • Related wiring
harness
• CMP sensor
Cylinder (See 01-40B-11 Inspection Using An Oscilloscope
85 CMP sensor • Related wiring
identification (Reference).)
harness
Refrigerant
pressure is more
than the
1.0 or less • Refrigerant
Refrigerant Refrigerant
specification pressure switch
pressure signal pressure switch
86 While idling (medium pressure)
(medium (medium Refrigerant • Related wiring
pressure) pressure) pressure is less
B+ harness
than the
specification
• Front HO2S (LH)
87 Front HO2S (LH) • Related wiring
(LH) (Reference).)
harness
Ignition switch at ON Approx. 0 • MAF sensor
88 Intake air amount MAF sensor After warm-up, while idling (no • Related wiring
Approx. 0.7 harness
electrical load, A/C off, P/S off)
Accelerator
Approx. 0.9 • TP sensor
Ignition switch at closed
89 Throttle position TP sensor • Related wiring
ON Accelerator fully
Approx. 4.7 harness
opened
• TP sensor
TP sensor,
Constant voltage Ignition switch • D.P.F. EGR sensor
90 D.P.F. EGR Approx. 5.0
power supply On • Related wiring
sensor
harness
01-40B–10
TP sensor,
MAF/IAT
sensor, HO2S,
Input device D.P.F. EGR • Related wiring
91 Under any condition 1.0 or less
ground sensor, ECT harness
sensor, TFT
sensor, TR
switch sensor
When brake pedal is depressed B+ • Brake switch
01
92 Brake Brake switch • Related wiring
Except above 1.0 or less harness
Front HO2S • Front HO2S (RH)
93 heater (RH) • Related wiring
heater (RH) (Reference).)
control harness
Front HO2S • Front HO2S (LH)
94 heater (LH) • Related wiring
heater (LH) (Reference).)
control harness
• Rear HO2S (RH)
Rear HO2S
Rear HO2S Heavy load (Heater control not heater
95 heater (RH) B+
heater (RH) operating) • Related wiring
control
harness
• Rear HO2S (LH)
Rear HO2S
Rear HO2S Heavy load (Heater control not heater
96 heater (LH) B+
heater (LH) operating) • Related wiring
control
harness
Ignition switch at ON B+ • Main relay
97 Power supply Main relay Ignition switch is off. 1.0 or less • Related wiring
A/C off B+
harness
98 — — — — —
• Fuel injector
harness
• Fuel injector
harness
• Fuel injector
harness
102 — — — — —
• Related wiring
harness
104 — — — — —
Inspection Using An Oscilloscope (Reference)

Ignition coil control signal
0V
atraaw00000167
• Connection terminals:
No.1 cylinder: 26 (+)—Body ground (–)
01-40B–11
• Instrument setting: 5 V/DIV (Y), 10 ms/DIV (X), DC range
• Measurement condition: After warm-up, while idling (no electrical load, A/C off, P/S off)
Engine speed signal

(+)
0V
atraaw00000168
• Connection terminal: 21 (+)—Body ground (–)

(–)
•Connection terminal: 22 (+)—Body ground (–)
•Instrument setting: 2 V/DIV (Y), 5 ms/DIV (X), DC
range
• Measurement condition: After warm-up, while
idling (no electrical load, A/C off, P/S off) 0V
atraaw00000169
Purge solenoid valve control signal
ov
atraaw00000170

01-40B–12
Turbine speed signal
0V
01
atraaw00000171

• Instrument setting: 2 V/DIV (Y):10 ms/DIV (X), DC range
Oxygen concentration signal
0V
atraaw00000172
Right bank: 60 (+)—Body ground (–)
• Instrument setting: 0.1 V/DIV (Y), 1 s/DIV (X), DC range
Fuel injector control signals
0V
atraaw00000173
No. 1:75 (+)—Body ground (–)
01-40B–13
Electronic pressure control solenoid control
0V
atraaw00000174

• Instrument setting: 2 V/DIV (Y), 0.2 ms/DIV (X), DC range
IAC control signal
0V
atraaw00000175

• Instrument setting: 2 V/DIV (Y), 0.4 ms/DIV (X), DC range
Cylinder identification signal
0V
atraaw00000176

• Instrument setting: 0.5 V/DIV (Y), 20 ms/DIV (X), DC range
01-40B–14
HO2S heater control signal
0V
01
atraaw00000177
Left bank: 94 (+)—Body ground (–)
• Instrument setting: 2 V/DIV (Y):200 ms/DIV (X), DC range
End Of Sie
PCM CONFIGURATION[AJ (3.0L Duratec)]
id0140a1802600
1. Connect the PDS/IDS to DLC-2.
2. After the vehicle is identified, select the following
items from the initialization screen of the PDS/
IDS.
• When using the IDS (notebook PC)
1. Select the “Module Programming”.
• When using the PDS (pocket PC)
1. Select “Programming”.
2. Select “Module Programming”.
3. Then, select the “Programmable Module
Installation”, “PCM” from the screen menu.
DLC-2
4. Retrieve DTCs by the PDS/IDS, then verify that
aesffw00000039
there in no DTC present.
• If a DTC is present, perform the applicable
DTC inspection.
End Of Sie
POWER STEERING PRESSURE (PSP) SWITCH REMOVAL/INSTALLATION[AJ (3.0L Duratec)]
WM: POWER STEERING PRESSURE SWITCH
id0140a1805200
2. Perform air bleeding.
4. Remove the PSP switch. PSP SWITCH
PSP switch tightening torque

6.8—13.6 N·m {70—138 kgf·m, 61—120
in·lbf}
End Of Sie
atraaw00000193
01-40B–15
POWER STEERING PRESSURE (PSP) SWITCH INSPECTION[AJ (3.0L Duratec)]
id0140a1803100
3. Verify the continuity between the PSP switch terminals while rotating the steering wheel.
• If it cannot be verified, verify that P/S oil pump is normal and replace the PSP switch. (See 01-40B-15
POWER STEERING PRESSURE (PSP) SWITCH REMOVAL/INSTALLATION[AJ (3.0L Duratec)].)
malfunction, perform the “Circuit Open/Short Inspection”.

PSP SWITCH
B A

CONNECTOR
26 25 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
52 51 50 49 48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27
78 77 76 75 74 73 72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53
104103102 101100 99 98 97 96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79
atraaw00001460
Open circuit
— PSP switch terminal A and PCM terminal 31
— PSP switch terminal B and PCM terminal 91
Short circuit
— PSP switch terminal A and body ground
— PSP switch terminal A and power supply
— PSP switch terminal B and power supply
End Of Sie
WM: TEMPERATURE SENSOR
01-40B–16
ENGINE COOLANT TEMPERATURE (ECT) SENSOR REMOVAL/INSTALLATION[AJ (3.0L Duratec)]
id0140a1801900
Warning
• A hot engine can cause severe burns. Turn off the engine and wait until it is cool before removing
the ECT sensor.

2. Drain the engine coolant.
3. Disconnect the ECT sensor connector. 01
4. Remove the ECT sensor.
End Of Sie
ECT SENSOR
atraaw00003290
ENGINE COOLANT TEMPERATURE (ECT) SENSOR INSPECTION[AJ (3.0L Duratec)]

id0140a1802000
Note
• Before performing the following inspection, make sure to follow the procedure as indicated in the
troubleshooting flowchart. (See 00-00-2 HOW TO USE THIS MANUAL.)
1. Disconnect the ECT sensor connector.
2. Remove the ECT sensor. (See 01-40B-17 ENGINE COOLANT TEMPERATURE (ECT) SENSOR REMOVAL/
3. Place the detection part of the ECT sensor in water and while gradually increasing the water temperature,
measure the resistance between the ECT sensor terminals.
• If it is not within the specification, replace the ECT sensor. (See 01-40B-17 ENGINE COOLANT
TEMPERATURE (ECT) SENSOR REMOVAL/INSTALLATION[AJ (3.0L Duratec)].)
• If the monitor item status/specification (reference) is not within the specification, even though the resistance
is within the specification, perform the “Circuit Open/Short Inspection”.
Measure the ECT sensor resistance.

ECT (°C {°F}) Resistance (kilohm)
20 {68} 3540
80 {176} 3.64.1
ECT sensor characteristics graph (reference)

70
60
50
RESISTANCE
40
(KILOHM)
30
20
10
0
20 40 60 80 100
{68} {104} {140} {176} {212}
TEMPERATURE (°C {°F})
atraaw00000148
01-40B–17
ECT SENSOR
B A

CONNECTOR
26 25 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
52 51 50 49 48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27
78 77 76 75 74 73 72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53
104103102 101100 99 98 97 96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79
atraaw00001462
Open circuit
— ECT sensor terminal A and PCM terminal 38
— ECT sensor terminal B and PCM terminal 91
Short circuit
— ECT sensor terminal A and body ground
— ECT sensor terminal A and power supply
— ECT sensor terminal B and power supply
End Of Sie
MASS AIR FLOW (MAF) SENSOR REMOVAL/INSTALLATION[AJ (3.0L Duratec)]
WM: MASS AIR FLOW SENSOR
id0140a1804200
2. Remove the air hose. (See 01-13B-9 AIR HOSE REMOVAL/INSTALLATION[AJ (3.0L Duratec)].)
3. Disconnect MAF sensor connector.
atraaw00002407
01-40B–18
4. Remove the MAF sensor installation nuts.
5. Remove the MAF sensor.
MAF SENSOR
MAF sensor installation nut tightening torque
7 N·m {71 kgf·cm, 62 in·lbf}
End Of Sie
01
atraaw00002408
MASS AIR FLOW (MAF) SENSOR INSPECTION[AJ (3.0L Duratec)]

id0140a1800700
Note
Visual Inspection
1. Verify the following items of the MAF sensor.
• Damage, cracks
• Rusted sensor terminal
• Bent sensor terminal
— If there is any malfunction, replace the MAF sensor. (See 01-40B-18 MASS AIR FLOW (MAF)
SENSOR REMOVAL/INSTALLATION[AJ (3.0L Duratec)].)
Voltage Inspection
1. Remove the MAF sensor with the connector still connected.
3. Verify that the MAF sensor output voltage (PDS/IDS monitor item: MAF) changes when wind is introduced
gradually to the sensor part of the MAF sensor.
• If it cannot be verified even though the related harnesses have no malfunction, replace the MAF sensor.
(See 01-40B-18 MASS AIR FLOW (MAF) SENSOR REMOVAL/INSTALLATION[AJ (3.0L Duratec)].)
is within the specification, perform the “Circuit Open/Short Inspection“.

01-40B–19
MAF/IAT SENSOR
F E D C B A

CONNECTOR
26 25 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
52 51 50 49 48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27
78 77 76 75 74 73 72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53
104103102 101100 99 98 97 96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79
atraaw00001477
Open circuit
— MAF sensor terminal B and main relay terminal B
— MAF sensor terminal C and body GND
— MAF sensor terminal D and PCM terminal 36
— MAF sensor terminal E and PCM terminal 88
Short circuit
— MAF sensor terminal B and body GND
— MAF sensor terminal C and power supply
— MAF sensor terminal D and power supply
— MAF sensor terminal E and power supply
— MAF sensor terminal E and body GND
End Of Sie
INTAKE AIR TEMPERATURE (IAT) SENSOR INSPECTION[AJ (3.0L Duratec)]
WM: INTAKE AIR TEMPERATURE SENSOR
id0140a1802200
Note
1. Disconnect the MAF/IAT sensor connector.
2. Measure the resistance between MAF/IAT sensor
terminals A and F.
MAF/IAT sensor. (See 01-40B-18 MASS AIR
F E D C B A
FLOW (MAF) SENSOR REMOVAL/
• If the monitor item status/specification
even though the resistance is within the
specification, perform the “Circuit Open/Short
Inspection”.
atraaw00000196
01-40B–20
IAT sensor resistance
IAT (°C {°F}) Resistance (kilohm)
10 {50} Approx. 58.75
20 {68} Approx. 37.30
30 {86} Approx. 24.27
60 {140} Approx. 7.70
IAT sensor characteristics graph (reference)

01
70
60
50
RESISTANCE
40
(KILOHM)
30
20
10
0
20 40 60 80 100
{68} {104} {140} {176} {212}
TEMPERATURE (°C {°F})
atraaw00000197

MAF/IAT SENSOR
F E D C B A

CONNECTOR
26 25 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
52 51 50 49 48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27
78 77 76 75 74 73 72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53
104103102 101100 99 98 97 96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79
atraaw00001480
Open circuit
— IAT sensor terminal A and PCM terminal 91
— IAT sensor terminal F and PCM terminal 39
Short circuit
— IAT sensor terminal A and power supply
— IAT sensor terminal F and body ground
— IAT sensor terminal F and power supply
End Of Sie
WM: THROTTLE POSITION SENSOR
01-40B–21
THROTTLE POSITION (TP) SENSOR INSPECTION[AJ (3.0L Duratec)]
id0140a1802700
Note
troubleshooting flowchart. (See 01-03B-4 ENGINE SYMPTOM TROUBLESHOOTING[AJ (3.0L
Duratec)].)
1. Inspect for the following:
• Throttle valve closed status
• Accelerator cable play
2. Disconnect the TP sensor connector.
3. Verify that the resistance between TP sensor
terminals 1 and 2 changes moderately
corresponding to the throttle valve opening angle.
(reference) is not within the specification, C B A
Inspection”.
• If there is any malfunction, replace the throttle
body. (See 01-13B-9 THROTTLE BODY
REMOVAL/INSTALLATION[AJ (3.0L
Duratec)].)
atraaw00001492

TP SENSOR
C B A

CONNECTOR
26 25 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
52 51 50 49 48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27
78 77 76 75 74 73 72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53
104103102 101100 99 98 97 96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79
atraaw00001493
Open circuit
— TP sensor terminal A and PCM terminal 91
— TP sensor terminal B and PCM terminal 89
— TP sensor terminal C and PCM terminal 90
Short circuit
— TP sensor terminal A and power supply
— TP sensor terminal B and body ground
— TP sensor terminal B and power supply
— TP sensor terminal C and body ground
End Of Sie
01-40B–22
CRANKSHAFT POSITION (CKP) SENSOR REMOVAL/INSTALLATION[AJ (3.0L Duratec)]
WM: CRANKSHAFT POSITION PLATE
id0140a1800600
3. Remove the front lower splash shield installation
bolts.
4. Remove the front lower splash shield.
01
atraaw00000161
5. Disconnect the CKP sensor connector.

6. Remove the CKP sensor installation bolts.
7. Remove the CKP sensor.
CKP sensor installation bolt tightening

torque.
8—12 N·m {82—122 kgf·cm, 71—106 in·lbf}
Front lower splash shield installation bolt
tightening torque CKP SENSOR
6.9—9.8 N·m {70—100 kgf·cm, 61—86 in·lbf}
Front lower splash shield installation nut
atraaw00000162
tightening torque
8.9—12.7 N·m {90—130 kgf·cm, 67.8—112
in·lbf}
End Of Sie
CRANKSHAFT POSITION (CKP) SENSOR INSPECTION[AJ (3.0L Duratec)]
id0140a1800500
Note
Visual Inspection
1. Remove the CKP sensor. (See 01-40B-23 CRANKSHAFT POSITION (CKP) SENSOR REMOVAL/
2. Verify that there are no metal shavings on the CKP sensor.
3. Install the CKP sensor. (See 01-40B-23 CRANKSHAFT POSITION (CKP) SENSOR REMOVAL/
1. Remove the CKP sensor connector.
2. Measure the resistance between the CKP sensor terminals.
• If not within the specification, replace the CKP sensor. (See 01-40B-23 CRANKSHAFT POSITION (CKP)
CKP sensor resistance

267—325 ohms
01-40B–23
OKP SENSOR
B A

CONNECTOR
26 25 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
52 51 50 49 48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27
78 77 76 75 74 73 72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53
104103102 101100 99 98 97 96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79
atraaw00001517
Open circuit
— CKP sensor terminal A and PCM terminal 21
— CKP sensor terminal B and PCM terminal 22
Short circuit
— CKP sensor terminal A and power supply
— CKP sensor terminal A and body ground
— CKP sensor terminal B and power supply
— CKP sensor terminal B and body ground
End Of Sie
CAMSHAFT POSITION (CMP) SENSOR REMOVAL/INSTALLATION[AJ (3.0L Duratec)]
WM: CAMSHAFT POSITION SENSOR
id0140a1801500
2. Disconnect the CMP sensor connector.
3. Remove the CMP sensor installation bolt. CMP SENSOR
4. Remove the CMP sensor.
CMP sensor installation bolt tightening torque

8—12 N·m {82—122 kgf·cm, 71—106 in·lbf}
End Of Sie
atraaw00000163
01-40B–24
CAMSHAFT POSITION (CMP) SENSOR INSPECTION[AJ (3.0L Duratec)]
id0140a1801400
Note
Visual Inspection
1. Remove the CMP sensor. (See 01-40B-24 CAMSHAFT POSITION (CMP) SENSOR REMOVAL/
INSTALLATION[AJ (3.0L Duratec)].) 01
2. Verify that there are no metal shavings on the CMP sensor.
3. Install the CMP sensor. (See 01-40B-24 CAMSHAFT POSITION (CMP) SENSOR REMOVAL/
Voltage Inspection
1. Idle the engine.
Caution
2. Measure the CMP sensor voltage using a oscilloscope.

• If not within the specification, replace the CMP sensor. (See 01-40B-24 CAMSHAFT POSITION (CMP)
Measurement condition
• Connection terminals: 85(+) — GND(–)
• Instrument setting: DC range
• Measurement condition: cranking while circuit opening relay is disconnected.
CMP sensor output voltage
MAXIMUM
VOLTAGE: 8.0 V
OR MORE
MINIMUM
VOLTAGE: 2.0 V
atraaw00000195
01-40B–25
CMP SENSOR
B A

CONNECTOR
26 25 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
52 51 50 49 48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27
78 77 76 75 74 73 72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53
104103102 101100 99 98 97 96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79
atraaw00001518
Open circuit
— CMP sensor terminal A and PCM terminal 85
— CMP sensor terminal B and PCM terminal 3
Short circuit
— CMP sensor terminal A and power supply
— CMP sensor terminal A and body ground
— CMP sensor terminal B and power supply
End Of Sie
FRONT HEATED OXYGEN SENSOR (HO2S) REMOVAL/INSTALLATION[AJ (3.0L Duratec)]
WM: HEATED OXYGEN SENSOR
id0140a1804800
HO2S (LH) Removal/Installation
3. Fold back the splash shield.
4. Disconnect the HO2S (LH) connector.
Note
• If necessary, lubricate the HO2S with
Penetrating and Lock Lubricant loosen to aid
in removal.
atraaw00000185
01-40B–26
5. Using the SST, remove the HO2S (LH).
49 L018 001
Note
• Apply a light coat meeting specification
silicone sealant TB1107 or equivalent to the
threads of the HO2S to aid in installation.
HO2S (LH) tightening torque

01
29—49 N·m {3.0—4.9 kgf·m, 22—36 ft·lbf}
atraaw00000186
HO2S (RH) Removal/Installation

2. Disconnect the HO2S (RH) connector.
3. Position the PCM harness protector tightening nut
out of the way with the connectors still connected.
Note
• If necessary, lubricate the HO2S with
in removal.
atraaw00000187
4. Remove the HO2S using the SST.

49 L018 001
Note
threads of the HO2S to aid in installation.
HO2S (RH) tightening torque

29—49 N·m {3.0—4.9 kgf·m, 22—36 ft·lbf}
atraaw00000188
End Of Sie
FRONT HEATED OXYGEN SENSOR (HO2S) INSPECTION[AJ (3.0L Duratec)]
id0140a1804700
Note
Front Heated Oxygen Sensor (HO2S) Voltage Inspection

1. Warm UP the engine to normal operating temperature.
2. Using the PDS/IDS, monitor the following:
— Front HO2S voltage (PID: O2S11, O2S21)
01-40B–27
4. Verify that the front HO2S outputs a voltage of 0.6 V or more, one time or more, then verify that the front HO2S
voltage (PID: O2S11, O2S21) is 0.3 V is or less while decelerating as shown in the figure.
VSS
0 KPH
3000 RPM
2000 RPM
RPM
1000 RPM
0 RPM
1V
O2S11, 0.5V
O2S21 0.3V OR LESS
0V
aesffw00000516
• If not within the specification, inspect the front HO2S for an open or short circuit. (See 01-40B-27 Front
Heated Oxygen Sensor (HO2S) Voltage Inspection.) Then if there is no malfunction in the wiring harness,
replace the front HO2S. (See 01-40B-26 FRONT HEATED OXYGEN SENSOR (HO2S) REMOVAL/
HO2S Heater Resistance Inspection

1. Disconnect the HO2S connector.
2. Measure the resistance between HO2S terminals
C and A.
HO2S. (See 01-40B-26 FRONT HEATED C A
OXYGEN SENSOR (HO2S) REMOVAL/
INSTALLATION[AJ (3.0L Duratec)].) D B
Inspection”.
atraaw00000198
HO2S heater resistance
2—50 ohms
01-40B–28
FRONT HO2S SENSOR
C A
D B 01
PCM
26 25 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
52 51 50 49 48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27
78 77 76 75 74 73 72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53
104103102 101100 99 98 97 96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79
atraaw00001585
Open circuit
— HO2S (RH) terminal A and PCM terminal 93
— HO2S (RH) terminal B and PCM terminal 60
— HO2S (RH) terminal C and main relay terminal B
— HO2S (RH) terminal D and PCM terminal 31
— HO2S (LH) terminal A and PCM terminal 94
— HO2S (LH) terminal B and PCM terminal 87
— HO2S (LH) terminal C and main relay terminal B
— HO2S (LH) terminal D and PCM terminal 31
Short circuit
— HO2S (RH) terminal A and power supply
— HO2S (RH) terminal A and body ground
— HO2S (RH) terminal B and power supply
— HO2S (RH) terminal B and body ground
— HO2S (RH) terminal C and body ground
— HO2S (RH) terminal D and power supply
— HO2S (LH) terminal A and power supply
— HO2S (LH) terminal A and body ground
— HO2S (LH) terminal B and power supply
— HO2S (LH) terminal B and body ground
— HO2S (LH) terminal C and body ground
— HO2S (LH) terminal D and power supply
End Of Sie
01-40B–29
REAR HEATED OXYGEN SENSOR (HO2S) REMOVAL/INSTALLATION[AJ (3.0L Duratec)]
id0140a1805000
HO2S (LH) Removal/Installation
3. Fold back the splash shield.
4. Disconnect the HO2S (LH) connector.
Note
• If necessary, lubricate the HO2S (LH) with
in removal.
atraaw00000189
5. Using the SST, remove the HO2S (LH).
Note
threads of the HO2S (LH) to aid in
installation.
HO2S (LH) tightening torque 49 L018 001

29—49 N·m {3.0—4.9 kgf·m, 22—36 ft·lbf}
atraaw00000190
HO2S (RH) Removal/Installation

2. Disconnect the HO2S (RH) connector.
Note
• If necessary, lubricate the HO2S (RH) with
in removal.
atraaw00000191
3. Remove the HO2S (RH) using the SST.
Note 49 L018 001

threads of the HO2S (RH) to aid in
installation.
HO2S (RH) tightening torque

29—49 N·m {3.0—4.9 kgf·m, 22—36 ft·lbf}
atraaw00000192
End Of Sie
01-40B–30
REAR HEATED OXYGEN SENSOR (HO2S) INSPECTION[AJ (3.0L Duratec)]
id0140a1804900
Note
Rear Heated Oxygen Sensor (HO2S) Voltage Inspection

1. Warm UP the engine to normal operating temperature.
2. Using the PDS/IDS, monitor the following: 01
— Rear HO2S voltage (PID: O2S12, O2S22)
4. Verify that the rear HO2S outputs a voltage of 0.6 V or more, one time or more, then verify that the rear HO2S
voltage (PID: O2S12, O2S22) is 0.3 V is or less while decelerating as shown in the figure.
VSS
0 KPH
3000 RPM
2000 RPM
RPM
1000 RPM
0 RPM
1V
O2S12,
O2S22 0.5V
0.3V OR LESS
0V
aesffw00000517
• If not within the specification, inspect the rear HO2S for an open or short circuit. Then if there is no
malfunction in the wiring harness, replace the rear HO2S. (See 01-40B-30 REAR HEATED OXYGEN
SENSOR (HO2S) REMOVAL/INSTALLATION[AJ (3.0L Duratec)].)
HO2S Heater Resistance Inspection

1. Disconnect the HO2S connector.
2. Measure the resistance between HO2S terminals
C and A.
HO2S. (See 01-40B-30 REAR HEATED C A
OXYGEN SENSOR (HO2S) REMOVAL/ D B
Inspection”.
atraaw00000199
HO2S heater resistance
250 ohms
01-40B–31
REAR HO2S SENSOR
C A
D B
PCM
26 25 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
52 51 50 49 48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27
78 77 76 75 74 73 72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53
104103102 101100 99 98 97 96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79
atraaw00001593
Open circuit
— HO2S (RH) terminal A and PCM terminal 95
— HO2S (RH) terminal B and PCM terminal 35
— HO2S (RH) terminal C and main relay terminal B
— HO2S (RH) terminal D and PCM terminal 31
— HO2S (LH) terminal A and PCM terminal 96
— HO2S (LH) terminal B and PCM terminal 61
— HO2S (LH) terminal C and main relay terminal B
— HO2S (LH) terminal D and PCM terminal 31
Short circuit
— HO2S (RH) terminal A and power supply
— HO2S (RH) terminal A and body ground
— HO2S (RH) terminal B and power supply
— HO2S (RH) terminal B and body ground
— HO2S (RH) terminal C and body ground
— HO2S (RH) terminal D and power supply
— HO2S (LH) terminal A and power supply
— HO2S (LH) terminal A and body ground
— HO2S (LH) terminal B and power supply
— HO2S (LH) terminal B and body ground
— HO2S (LH) terminal C and body ground
— HO2S (LH) terminal D and power supply
End Of Sie
WM: DIFFERENTIAL PRESSURE FEEDBACK EGR SENSOR
01-40B–32
DIFFERENTIAL PRESSURE FEEDBACK (D.P.F.) EGR SENSOR REMOVAL/INSTALLATION[AJ (3.0L
Duratec)]
id0140a1804600
2. Disconnect the differential pressure feedback EGR sensor connector.
01
R
D.P.F. EGR SENSOR
atraaw00000194
3. Remove the differential pressure feedback EGR sensor from EGR tube by pulling it out.
End Of Sie
DIFFERENTIAL PRESSURE FEEDBACK (D.P.F.) EGR SENSOR INSPECTION[AJ (3.0L Duratec)]
id0140a1804500
1. Remove the differential pressure feedback EGR sensor with the connector still connected.
2. Install the vacuum pump to the narrower diameter of the differential pressure feedback EGR sensor.
3. Connect the PDS/IDS.
5. Using PDS/IDS, verify that the DPFEGR PID value is as indicated in the table.
• If not within the specification even though the related wiring harnesses have no malfunction, replace the
differential pressure feedback EGR sensor. (See 01-40B-33 DIFFERENTIAL PRESSURE FEEDBACK
(D.P.F.) EGR SENSOR REMOVAL/INSTALLATION[AJ (3.0L Duratec)].)
Differential pressure feedback EGR sensor standard

Measurement condition DPFEGR PID value
Vacuum pump vacuum 0 kPa 0.2—1.3 V
Vacuum pump vacuum 27—30 kPa More than 4.0 V
Within 3 s just after releasing air from the vacuum Less than 1.5 V
01-40B–33
D.P.F. EGR SENSOR
B A

CONNECTOR
26 25 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
52 51 50 49 48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27
78 77 76 75 74 73 72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53
104103102 101100 99 98 97 96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79
atraaw00001594
Open circuit
— D.P.F. EGR sensor terminal A and PCM terminal 90
— D.P.F. EGR sensor terminal B and PCM terminal 91
— D.P.F. EGR sensor terminal C and PCM terminal 85
Short circuit
— D.P.F. EGR. sensor terminal A and body GND
— D.P.F. EGR. sensor terminal B and power supply
— D.P.F. EGR. sensor terminal C and power supply
— D.P.F. EGR. sensor terminal C and body GND
End Of Sie
01-40B–34
TECHNICAL DATA [L3]
01-50A TECHNICAL DATA [L3]

ENGINE TECHNICAL DATA[L3]. . . . . . . 01-50A–1
End of Toc
ENGINE TECHNICAL DATA[L3]
WM: ENGINE
id0150a2800100
Item Specification
IN: 0.22—0.28 mm {0.0087—0.0110 in}
01
Valve clearance [Engine cold]
EX: 0.27—0.33 mm {0.0106—0.0130 in}
Standard: 1,430 kPa {14.5819 kgf/cm2, 207.404 psi}[290 rpm]
Compression pressure Minimum: 1,000 kPa {10.197 kgf/cm2, 145.00 psi}[290 rpm]
Maximum difference between cylinders: 196.1 kPa {2.0 kgf/cm2, 28.5
psi}
Cylinder head bolt length L 145.2—145.8 mm {5.72—5.74 in}
Cylinder head bolt maximum 146.5 mm {5.77 in}
Oil control valve resistance 6.9—7.9 ohms [20°C {68°F}]
Ignition timing Approx. BTDC 8°
No load: 650—750 rpm
Idle speed (N position) Electrical loads on*1: 650—750 rpm
P/S operation: 650—750 rpm
A/C operation: 650—750 rpm
Idle mixture
Oil pressure (reference value) [oil temperature: 100 °C
{212 °F}] 337—591 kPa {3.44—6.03 kgf/cm2, 49.0—85.8 psi}[3,000 rpm]
Engine oil capacity (approx. quantity) Oil and oil filter replacement: 4.4 L {4.6 US qt, 3.9 Imp qt}
Engine coolant capacity (approx. quantity) 7.5 L {7.9 US qt, 6.6 Imp qt}
Cooling system cap valve opening pressure 93.2—122.6 kPa {0.95—1.25 kgf/cm2, 13.5—17.8 psi}
Thermostat initial-opening temperature 80—84 °C {176—183 °F}
Thermostat full-open temperature 97 °C {207 °F}
Thermostat full-open lift More than 8.0 mm {0.31 in}
No.1: 3.6—6.6 A
Cooling fan motor standard current
No.2: 7.7—10.7 A
Battery electrolyte specific gravity [20 °C {68 °F}] 1.22—1.29
Battery load test current 55D23L (48): 180 A
Battery slow charge current 55D23L (48): Approx. 4.8 A (10 h)
Terminal B: B+
Generator standard voltage [IG-ON] Terminal P: Approx. 1 V or less
Terminal D: Approx. 0 V
Terminal P: Approx. 3—8 V
Generator standard voltage [Idle, 20 °C {68 °F}]
Terminal D: Turn the electrical loads (headlights, blower motor, rear
window defroster) on and verify that the voltage reading increases.
70 % of the nominal output current (nominal output current: 110 A)
Generator generated current minimum value [Ambient temp. 20 °C {68 °F}, voltage 13.0—15.0 V, both engine and
generator are hot]
Generator rotor resistance (between slip rings) [20 °C
1.8—2.2 ohm
{68 °F}]
Standard: 22.5 mm {0.89 in}
Generator brush length
Minimum: 5.0 mm {0.20 in}
Standard: 4.1—5.3 N {0.42—0.54 kgf, 0.92—1.19 lbf}
Generator brush spring force
Minimum: 1.7 N {0.17 kgf, 0.38 lbf}
01-50A–1
TECHNICAL DATA [L3]
Item Specification
1-3-4-2 (all cylinders independent firing)
CYLINDER No.
CRANKSHAFT
ENGINE
PULLEY
Firing order 1
Spark plug type LFG1 18 110 (ILTR5A-13G), L3Y2 18 110

Spark plug gap 1.25—1.35 mm {0.050—0.053 in}
Spark plug resistance [25 °C {77 °F}] 3.0—7.5 kilohms
Starter no-load test voltage 11 V
Starter no-load test current 90 A or less
*1 : Blower motor is operating at high speed. Headlight switch is turned on. Rear window defroster switch is turned
on. Cooling fans are operating.

Item Specification
Grade API SG/SH/SJ/SL or ILSAC GF–2/GF–3
40, 30, 20, 20W–20, 10W–30, 10W–40, 10W–50,
Viscosity (SAE)
20W–40, 15W–40, 20W–50, 15W–50, 5W–20, 5W–30
End Of Sie
01-50A–2
TECHNICAL DATA [AJ (3.0L Duratec)]
01-50B TECHNICAL DATA [AJ (3.0L Duratec)]

ENGINE TECHNICAL DATA
[AJ (3.0L Duratec)] . . . . . . . . . . . . . . . . 01-50B–1
End of Toc
ENGINE TECHNICAL DATA[AJ (3.0L Duratec)]
WM: ENGINE
id0150a1800100
Item Specification
01
Valve clearance 0 mm {0 in} Maintenance-free
Standard: 1,480 kPa {15.10 kgf/cm2, 215 psi} [210 rpm]
Compression pressure Compression pressure of lowest cylinder must be within 75 % of
highest (See 01-10B-6 COMPRESSION INSPECTION[AJ (3.0L
Duratec)].)
2.5—3.0 mm {0.10—0.11 in} (from the edge of the camshaft oil seal
Pushing distance of the camshaft oil seal
housing)
Pushing distance of the front oil seal 0—1.0 mm {0—0.039 in} (from the edge of the engine front cover)
Pushing distance of the rear oil seal 0—2.0 mm {0—0.078 in} (from the edge of the cylinder block)
Ignition timing BTDC 8 °—12 ° (700—800 rpm)
Idle speed 600—900 rpm (P-position)
Idle mixture
Oil pressure (reference value) [oil temperature: 100 °C
{212 °F}] 103 kPa {1.1 kgf/cm2, 15 psi} min [1,500 rpm]
Engine oil capacity (approx. quantity) Oil and oil filter replacement: 5.7 L {6.0 US qt, 5.0 Imp qt}
Engine coolant capacity (approx. quantity) 10.0 L {10.6 US qt, 8.80 Imp qt}
Cooling fan motor No.1, No,2 standard current Approx. 20 A
Cooling system cap valve opening pressure 93.2—122.6 kPa {0.95—1.25 kgf/cm2, 13.5—17.8 psi}
Thermostat initial-opening temperature 84—88 °C {184—190 °F}
Thermostat full-open temperature 99 °C {210 °F}
Thermostat full-open lift More than 7.3 mm {0.29 in}
Fuel line pressure 420—460 kPa {4.3—4.6 kgf/cm2, 61—66 psi}
Fuel line hold pressure Approx. 408 kPa {4.16 kgf/cm2, 59.1 psi} or more
Fuel injector leakage amount 1 drop or less/2 min
Battery electrolyte specific gravity [20 °C {68 °F}] 1.22—1.29
Battery load test current 80D26L (55): 195 A
Battery slow charge current 80D26L (55): Approx. 5.5 A (10 h)
Terminal B: B+
Generator standard voltage [IG-ON] Terminal L: Approx. 1 V or less
Terminal S: B+
Generator standard voltage [Idle, 20 °C {68 °F}] Terminal L: 13—15 V
Terminal S: 13—15 V
58 A [Generator terminal B voltage: 13.0—15.0 V, engine speed:
2,000 rpm]
Ignition coil primary coil resistance (reference) [25 °C
0.45—1.15 ohms
{77 °F}]
Ignition coil secondary coil resistance (reference) [25
5.0—6.0 kilohms
°C {77 °F}]
Ignition coil insulation resistance of case (reference)
10 Megohms
[25 °C {77 °F}]
01-50B–1
TECHNICAL DATA [AJ (3.0L Duratec)]
Item Specification
1-4-2-5-3-6
CYLINDER No.
CRANKSHAFT
PULLEY ENGINE
Firing order 4 1
5 2
6 3
LH RH
Spark plug type AJ11 18 110 (AGSF-32N)
Spark plug gap 1.32—1.42 mm {0.052—0.055 in}
Spark plug resistance [25 °C {77 °F}] 2.0—20.0 kilohms
Starter no-load test voltage 11 V
Starter no-load test current 90 A or less

Item Specification
Grade API SM or ILSAC GF–4
Viscosity (SAE) 5W–30
End Of Sie
01-50B–2
SERVICE TOOLS [L3]
01-60A SERVICE TOOLS [L3]

ENGINE SST[L3]. . . . . . . . . . . . . . . . . . . 01-60A–1
End of Toc
ENGINE SST[L3]
WM: ENGINE
id0160b2800100
1: Mazda SST number
2: Global SST number 01
Example
1:49 UN01 052
2:310–D005
Spring lock
coupler tool
(green)
1: 49 C017 1: 49 L017 5A0 1:49 UN20 5072

5A0*1 2: – 2:205–072
2: –
Support hanger Holder
Engine support
set
1:49 UN20 1:49 H010 401 1:49 JE01 061

507202 2:– 2:303–507
2:205–072–02
Oil seal installer Crankshaft TDC
Adapter timing pin
1:49 UN30 3376 1:49 0187 280A 1:49 E019 001

2: 303–376 2:– 2:–
Camshaft Oil pressure Adapter

alignment gauge
timing tool
1:49 H019 002 1:49 G032 354 1:49 L018 001

2: – 2: – 2:–
Adapter Adjusting O2 sensor

wrench wrench
1:49 D015 001 1:49 9200 145 1:49 UN30 3328

2:– 2:– 2:303–328
Wrench Radiator cap Rear oil seal

tester adapter replacer
set
1: 49 N013 1: 49 N013 1: 49 UN01 054
1A0D 103A 2: 310-041
2: – 2: –
Disconnect tool
Fuel pressure Remover (Part
gauge set of 49 N013
1A0D)
01-60A–1
SERVICE TOOLS [L3]
1: 49 E042 001 1: –
2: – 2: 310-069
Remover Wrench –
*1 : The SST (49 E017 5A0) can be used in place of the SST (49 C017 5A0).
End Of Sie
01-60A–2
SERVICE TOOLS [AJ (3.0L Duratec)]
01-60B SERVICE TOOLS [AJ (3.0L Duratec)]

ENGINE SST[AJ (3.0L Duratec)] . . . . . . 01-60B–1
End of Toc
ENGINE SST[AJ (3.0L Duratec)]
WM: ENGINE
id0160a2800100
1: Mazda SST number
2: Global SST number 01
Example
1: 49 C017
5A0*1
2: –
Engine support
1: 49 C017 1: 49 L017 5A0 1: 49 UN30

5A0*1 2: – 3050
2: – 2: 303-050
Support hanger
Engine support Engine lifting
bracket
1: 49 E011 1A1 1: 49 H012 006 1: 49 S120 710

2: – 2: – 2: –
Holder set Bolt Coupling flange

holder
1: 49 0187 1: 49 L014 1: 49 UN21
280A 001A 1185
2: – 2: – 2: 211-185
Oil pressure Pressure gauge Pump pulley

gauge attachment replacer
1: 49 UN30 1: 49 UN30 1: 49 UN30

3464 3463 3456
2: 303-464 2: 303-463 2: 303-456
Camshaft seal Camshaft seal Water pump

replacer protector pulley plate
1: 49 UN30 1: 49 UN30 1: 49 UN01 002
3457 3009 2: 303-102
2: 303-457 2: 303-009
Crankshaft
Shaft protector Crankshaft damper
damper replacer
remover
1: 49 D032 316 1: 49 UN30 1: 49 UN01 070
2: – 3335 2: 303-178
2: 303-335
Protractor Crankshaft seal
Crankshaft seal installer
installer/aligner
1: 49 UN30 1: 49 UN01 052 1: 49 L018 001
3384 2: 310-D005 2: –
2: 303-384
Spring lock O2 sensor
Rear crankshaft coupler tool wrench
adapter bolts
01-60B–1
SERVICE TOOLS [AJ (3.0L Duratec)]
1: 49 9200 145 1: 49 N013 1: 49 N013
2: – 1A0D 103A
2: – 2: –
Radiator cap
tester adapter Fuel pressure Remover (Part
set gauge set of 49 N013
1A0D)
1: 49 UN01 054 1: 49 E042 001 1: –

2: 310-041 2: – 2: 310-069
Disconnect tool Remover Wrench
*1 : The SST (49 E017 5A0) can be used in place of the SST (49 C017 5A0).
End Of Sie
01-60B–2
SUSPENSION 02
SECTION
Toc of SCT PROCEDURES . . . 02-10

GENERAL REAR SUSPENSION . . . . . . . . 02-14
WHEEL ALIGNMENT . . . . . . . 02-11 TECHNICAL DATA . . . . . . . . . . 02-50
WHEEL AND TIRES . . . . . . . . 02-12 SERVICE TOOLS . . . . . . . . . . . 02-60
FRONT SUSPENSION. . . . . . . 02-13
Toc of SCT
02-10 GENERAL PROCEDURES
SUSPENSION SYSTEM
02
DIAGNOSIS/TESTING . . . . . . . . . . . . . 02-10–2
End of Toc
WM: SUSPENSION
02-10–1
GENERAL PROCEDURES
SUSPENSION SYSTEM DIAGNOSIS/TESTING
id021000800200
Front Suspension Inspection/Verification
Caution
• Always perform a preliminary inspection of the front end components before adjusting the front
wheel alignment.
1. Prior to inspection, perform the following procedures:

(1) Fill all fluids to specification.
(2) Make sure that the spare tire and related equipment are correctly stored.
(3) Remove any mud, dirt, or road deposits from the chassis and underbody.
(4) Maintain the vehicle at a normal load. Inflate all tires to the recommended pressure.
(5) Verify that both front tires are the specified size.
(6) Inspect the lower arm ball joints for wear or damage. (See 02-13-6 FRONT LOWER ARM INSPECTION.)
(7) Inspect the steering components for wear or damage. (See 06-10-2 STEERING SYSTEM DIAGNOSIS/
TESTING.)
(8) Inspect the steering gear and mounting bolts and tighten to the specified torque. (See 06-14-19 STEERING
GEAR AND LINKAGE REMOVAL/INSTALLATION[L3].) (See 06-14-21 STEERING GEAR AND LINKAGE
Wheel bearings
1. Inspect the front wheel bearing for seizing or damage.
2. Inspect the wheel hub for cracks or damage to the casting.
Shock absorber and coil spring

1. Visually inspect each component of the shock absorber and spring and replace if necessary. (See 02-13-2
FRONT SHOCK ABSORBER AND COIL SPRING REMOVAL/INSTALLATION.) (See 02-14-1 REAR SHOCK
ABSORBER REMOVAL/INSTALLATION.) (See 02-14-2 REAR COIL SPRING REMOVAL/ INSTALLATION.)
2. Inspect the shock absorbers for weepage or leaks. Verify that the oil is not from sources other than the shock
absorber.
• Weepage is a condition that:
— deposits a thin film of oil on the shock absorber.
— is normally noticed due to a collection of dust on the shock absorber.
— occurs during the normal break-in period of 4,800—8,050 km {3,000—5,000 mile}. After this period, no
new signs of oil should be visible.
— does not require replacement of the shock absorber.
• Leakage is a condition that:
— covers the entire shock absorber with oil.
— will drip oil onto surrounding suspension components.
— requires replacement of the shock absorber.
3. Inspect the shock absorbers using the following procedure:
(1) Remove the suspected shock absorbers. (See 02-13-2 FRONT SHOCK ABSORBER AND COIL SPRING
REMOVAL/INSTALLATION.) (See 02-14-1 REAR SHOCK ABSORBER REMOVAL/INSTALLATION.)
Extend the piston rod when removing the shock absorber.
(2) Compress the LH and RH piston rods. Both should offer the same resistance when compressed.
(3) Compress and release the LH and RH piston rods. The piston rods should extend equally after being
released.
4. If any malfunction is found during the above test, replace the shock absorber(s).
Vehicle Inspection
1. Inspect all tires for specified inflation pressure.
2. Inspect the tire condition and verify that the front wheel alignment, wheel balance, and overall tire condition
(such as separation or bulging) are normal.
3. Inspect the vehicle for overloading or sagging.
4. Road test the vehicle to verify the customer concern.
5. Replace insulators and bushings with new ones as necessary. Tighten all component parts to the specified
torque. (See 02-13-2 FRONT SHOCK ABSORBER AND COIL SPRING REMOVAL/INSTALLATION.) (See 02-
14-1 REAR SHOCK ABSORBER REMOVAL/INSTALLATION.)
Rear Suspension Inspection/Verification

1. At regular intervals, inspect the condition of the rear suspension arms and bushings. Install new parts as
necessary.
02-10–2
GENERAL PROCEDURES
Symptom Troubleshooting Chart
1. Verify the symptom, and conduct corresponding diagnosis.
Troubleshooting Item Possible Cause No.
Drift left or right • Tire 1
• Steering gear and linkage
• Wheel alignment
• Brakes system components
Steering wheel off-center • Wheel Alignment 2
• Steering gear and linkage
• Front lower arm ball joint
Tracks incorrectly • Rear suspension 3
• Caster
Rough ride • Front shock absorber components 4
• Rear shock absorber and spring 02
Excessive noise • Front stabilizer components 5
• Coil spring
• Suspension components
• Shock absorber
Uneven tire wear • Wheel and tire unbalance 6
• Tire inflation
• Shock absorber
• Wheel alignment
Vibration • Wheels and tires 7
• Front drive shaft
• Steering system components
• Shock absorber components
• Coil spring and strut mount
• Hub bolts and wheel nuts
• Front lower arm ball joint
• Front lower arm bushings
• Stabilizer and control links
• Wheel hubs and bearings
• Rear suspension arms and bushings
• Disc plate
Vehicle lean • Wheels and tires 8
• Vehicle load
• Suspension components
• Incorrect ride height
Poor steering return • High knuckle rotating torque 9
• Power steering fluid level
• Wheel alignment
No. 1 Drift Left or Right

Diagnostic procedure
STEP INSPECTION ACTION
1 INSPECT TIRES FOR EXCESSIVE WEAR OR Yes Go to the next step.
DAMAGE No Replace the tires.
Are the tires normal?
2 INSPECT STEERING GEAR AND LINKAGE Yes Go to the next step.
Lift up the vehicle. No Repair or replace steering components, as necessary.
Inspect the steering system for excessive wear
and damage.
(See 06-10-2 STEERING SYSTEM
DIAGNOSIS/TESTING.)
Is the steering system normal?
3 INSPECT WHEEL ALIGNMENT Yes Go to the next step.
Is the wheel alignment within specification? No Adjust the wheel alignment.
(See 02-11-2 FRONT WHEEL ALIGNMENT.)
(See 02-11-5 REAR WHEEL ALIGNMENT.)
02-10–3
GENERAL PROCEDURES
4 INSPECT FOR BRAKE DRAG Yes Refer to steering system diagnosis/testing, and
Apply the brakes while driving. perform diagnosis.
Does drift or pull occur when the brakes are (See 06-10-2 STEERING SYSTEM DIAGNOSIS/
applied? TESTING.)
No If the steering wheel remains centered, the vehicle is
normal.
If the steering wheel is off-center, go to “No. 2 Steering
wheel off-center”.
(See 02-10-4 No. 2 Steering Wheel Off-center.)
No. 2 Steering Wheel Off-center

1 VISUALLY INSPECT STEERING WHEEL Yes Go to the next step.
DEVIATION No Adjust the steering wheel deviation to specification.
Is the steering wheel deviation within the
specification.
2 INSPECT STEERING GEAR AND LINKAGE Yes If the vehicle tracks correctly, then it is normal.
Lift up the vehicle. If the vehicle does not track correctly, go to “No. 3
Inspect the steering system for wear and Tracks incorrectly”.
damage. (See 02-10-4 No. 3 Tracks Incorrectly)
(See 06-10-2 STEERING SYSTEM No Repair or replace steering components, as necessary.
DIAGNOSIS/TESTING.)
Is the steering system normal?
No. 3 Tracks Incorrectly

1 INSPECT CASTER Yes Go to the next step.
Is the caster within specification? No Adjust the caster and camber.
2 INSPECT REAR SUSPENSION Yes If the ride is smooth, the vehicle is normal.
Measure the LH and RH wheel base. If the ride is not smooth, go to “No. 4 Rough ride”.
Compare the measurements. (See 02-10-4 No. 4 Rough Ride.)
Are the measurements the same? No Repair or replace rear suspension components, as
necessary.
No. 4 Rough Ride

1 INSPECT FRONT SHOCK ABSORBERS FOR Yes Replace the front shock absorbers.
OIL LEAKAGE OR DAMAGE (See 02-13-2 FRONT SHOCK ABSORBER AND COIL
Lift up the vehicle. SPRING REMOVAL/INSTALLATION.)
Do the front shock absorbers have oil leakage? No Go to the next step.
2 INSPECT REAR SHOCK ABSORBERS FOR Yes Replace the rear shock absorbers.
OIL LEAKAGE OR DAMAGE (See 02-14-1 REAR SHOCK ABSORBER REMOVAL/
Do the rear shock absorbers have oil leakage? INSTALLATION.)
No Vehicle is normal.
No. 5 Excessive Noise

1 INSPECT SUSPENSION SYSTEM Yes Tighten or replace the installation bolts.
Lift up the vehicle. (See 02-13-2 FRONT SHOCK ABSORBER AND COIL
Inspect the shock absorber installation bolts. SPRING REMOVAL/INSTALLATION.)
Are the installation bolts loose or damaged? (See 02-14-1 REAR SHOCK ABSORBER REMOVAL/
INSTALLATION.)
No Go to the next step.
02-10–4
GENERAL PROCEDURES
2 INSPECT COIL SPRINGS AND STABILIZERS Yes Go to the next step.
FOR DAMAGE No Replace the coil springs or stabilizers.
Are the coil springs and stabilizers normal? (See 02-13-2 FRONT SHOCK ABSORBER AND COIL
SPRING REMOVAL/INSTALLATION.)
(See 02-13-8 FRONT STABILIZER REMOVAL/
INSTALLATION.)
(See 02-13-8 STABILIZER CONTROL LINK
REMOVAL/INSTALLATION.)
(See 02-14-2 REAR COIL SPRING REMOVAL/
INSTALLATION.)
3 INSPECT FRONT SUSPENSION Yes Replace the front suspension components.
Are the front suspension components worn or No Vehicle is normal.
damaged?
02
No. 6 Uneven Tire Wear
1 INSPECT TIRES Yes Go to the next step.
Lift up the vehicle. No Adjust the wheel alignment. If the tires have significant
Inspect the tires for uneven wear on the inner wear, replace them.
and outer shoulders.
Are the tires normal?
2 INSPECT TIRE WEAR Yes Adjust the wheel alignment. If the tires have significant
Do the tires have a feathering wear pattern? wear, replace them.
No Go to the next step.
3 INSPECT TIRES FOR CUPPING OR DISHING Yes Adjust the wheel balance and rotate the tires.
Do the tires have any cupping or dishing? No Vehicle is normal.
No.7 Vibration
1 ROAD TEST Yes Go to the next step.
Accelerate the vehicle to the speed at which the No This is considered as a concern due to NVH. Identify
customer indicated the vibration occurs. NVH cause, and repair or replace.
Is vibration present?
2 INSPECT TIRES Yes Go to the next step.
Inspect the tires for unusual wear, cupping, or No Inspect the suspension components for misalignment,
flat spots. unusual wear, or damage that may have contributed to
Are the tires normal? tire wear.
Repair any malfunction, and adjust or replace the tires.
3 INSPECT WHEEL BEARINGS Yes Go to the next step.
Rotate the tires by hand and inspect the wheel No Replace wheel bearings, as necessary.
bearing play. (See 03-11-2 WHEEL HUB, STEERING KNUCKLE
Are the wheel bearings normal? REMOVAL/INSTALLATION.)
(See 03-12-2 REAR AXLE REMOVAL/
INSTALLATION.)
4 INSPECT WHEEL BALANCE Yes Go to the next step.
Is wheel balance normal? No Adjust wheel balance, as necessary.
5 INSPECT RUNOUT Yes Go to Step 7.
Perform the following measurements on all No Go to the next step.
wheels.
• high point of the tire and wheel total radial
runout
• high point of the wheel radial runout
• high point of the wheel lateral runout
Are the runouts as specified?
02-10–5
GENERAL PROCEDURES
6 TEMPORARILY INSTALL TIRES AND Yes Go to the next step.
INSPECT No Install the original wheels and tires one by one, road
Temporarily install a set of wheels and tires testing at each step until the damaged tire is identified.
known to be normal. Replace tires and wheels, as necessary.
Road test the vehicle.
If the vehicle still exhibits shaking or vibration,
note the vehicle speed and RPM at which it
occurs.
Is vibration present?
7 DIAGNOSE WHETHER CAUSE OF PROBLEM Yes This is considered as a concern due to NVH. Identify
IS IN ENGINE/TRANSAXLE OR DRIVE NVH cause, and repair or replace.
SHAFT/SUSPENSION No Perform diagnosis of the engine and ATX.
Rotate each of the four wheels independently to
identify the location generating the vibration.
For the rear wheels, use an on-car balance
machine.(2WD)
For the front wheels, accelerate to half the
critical speed (vibration occurred) observed in
the road test.
Is vibration present in the wheels?
No. 8 Vehicle Leans

1 INSPECT TIRE PRESSURE Yes Go to the next step.
Is tire inflation normal? No Adjust tire inflation.
2 INSPECT VEHICLE LOAD Yes Go to the next step.
Is load condition normal? No Adjust load volume, as necessary.
3 VISUALLY INSPECT SUSPENSION SYSTEM Yes Go to the next step.
Is the suspension system normal? No Repair or replace suspension components, as
necessary.
4 INSPECT VEHICLE HEIGHT Yes Vehicle is normal.
Is vehicle height normal? No Adjust vehicle height, as necessary.
(See 02-11-1 LEAN CORRECTION.)
No. 9 Poor Steering Return

1 INSPECT TIE-ROD ENDS AND LOWER ARM Yes Go to the next step.
BALL JOINTS FOR STICKING No Repair or replace component parts as necessary.
Are the tie-rod ends and lower arm ball joints
free of sticking?
2 INSPECT POWER STEERING FLUID LEVEL Yes Go to the next step.
Is the power steering fluid level normal? No Correct the power steering fluid level.
3 INSPECT WHEEL ALIGNMENT Yes Vehicle is normal.
Is the wheel alignment within the specification? No Adjust the wheel alignment.
End Of Sie
02-10–6
WHEEL ALIGNMENT
02-11 WHEEL ALIGNMENT

LEAN CORRECTION . . . . . . . . . . . . . . . 02-11–1 REAR WHEEL ALIGNMENT . . . . . . . . . . 02-11–5
FRONT WHEEL ALIGNMENT . . . . . . . . 02-11–2
End of Toc
LEAN CORRECTION
WM: SUSPENSION
id021100800400
Note
• When installing a new coil spring, install one with the same part number and spring code.
1. Measure the distance from the wheelhouse

opening to the center of the wheel and tire at the 02
same point on both sides of the vehicle.
2. If the difference exceeds 10 mm {0.39 in}, a lean
correction is necessary.
Compare the original with a new coil spring. Note
the difference.
3. Remove the higher side coil spring.
(1) If the original coil spring exceeds the height of
the new one by 10 mm {0.39 in} or more,
install the new coil spring in the vehicle. (See
02-13-2 FRONT SHOCK ABSORBER AND
aesffw00000436
COIL SPRING REMOVAL/INSTALLATION.)
(See 02-13-3 FRONT SHOCK ABSORBER
AND COIL SPRING DISASSEMBLY/ASSEMBLY.) (See 02-14-2 REAR COIL SPRING REMOVAL/
INSTALLATION.)
(2) If the original coil spring is shorter than the new one by 10 mm {0.39 in} or more, remove the low side coil
spring from the vehicle. (See 02-13-2 FRONT SHOCK ABSORBER AND COIL SPRING REMOVAL/
INSTALLATION.) (See 02-13-3 FRONT SHOCK ABSORBER AND COIL SPRING DISASSEMBLY/
ASSEMBLY.) (See 02-14-2 REAR COIL SPRING REMOVAL/ INSTALLATION.)
4. Compare all three coil springs and select the two most evenly matched for installation.
End Of Sie
WM: FRONT SUSPENSION
02-11–1
WHEEL ALIGNMENT
FRONT WHEEL ALIGNMENT
id021100800200
Specification (Unloaded)*1
Item Specification
Fuel gauge indication Empty 1/4 1/2 3/4 Full
Inner 37°06′
Maximum 215/70R16 tires
Outer 30°54′
steering angle
[Tolerance ±3°] 235/70R16 tires Inner 35°18′
Outer 29°48′
Tire L3: –1.0 {0.04}
(mm {in})
[Tolerance ±4 {±0.16}] AJ (3.0L Duratec): 3.0 {0.12}
Total toe-in
L3: –0°05′±0°14′
(degree)
AJ (3.0L Duratec): 0°14′±0°14′
Caster angle*2 1°47′24′′
[Tolerance ±1°]
Camber angle*2 L3: –0°28′48′′
[Tolerance ±1°] AJ (3.0L Duratec): –0°50′24′′
L3: 11°06′
Steering axis inclination (Reference value)
AJ (3.0L Duratec): 11°24′
*1 : Engine coolant and engine oil are at specified level. Spare tire, jack and tools are in designated position.
*2 : Difference between left and right must not exceed 1°30′.
Camber and Caster Adjustment

2. Remove the front shock absorber upper mounting
bracket nuts.
atraaw00000643
3. Push the front shock absorber upper mounting

bracket downward and turn it to the desired DIRECTION INDICATOR
position to set camber and caster. Both camber
and caster for front suspension are adjustable
within a maximum angle of 22’ minutes.
atraaw00000644
Difference from standard position

Direction indicator L3 AJ (3.0L Duratec)
Camber angle Caster angle Camber angle Caster angle
1 0° –0°22′ 12′′ 0°21′ 36′′ 0°
2 –0°21′ 36′′ –0°22′ 12′′ 0°21′ 36′′ –0°22′ 12′′
3 –0°21′ 36′′ 0° 0° –0°22′ 12′′
02-11–2
WHEEL ALIGNMENT
4. Tighten the front shock absorber upper mounting
bracket nuts. 72—92 N·m
{7.4—9.3 kgf·m,
54—67 ft·lbf}
atraaw00001822
Front Toe Adjustment

02
1. Start the engine and center the steering wheel.
2. Turn the engine off and lock the steering wheel in
position.
3. Inspect the toe settings. Follow the specifications.
atraaw00001823
4. Remove the clamps.
Note
• Do not allow the boots to twist when the front
wheel spindle tie rod is rotated.
atraaw00001824
5. Loosen the nuts.

(1) Clean and lubricate the nuts and front wheel
spindle tie rod threads.
atraaw00001825
02-11–3
WHEEL ALIGNMENT
6. Rotate the nuts and the front wheel spindle tie
rods.
atraaw00001826
7. Tighten the nuts.

68.6—98.1 N·m
{7.0—10.0 kgf·m,
50.6—72.3 ft·lbf}
atraaw00001827
8. Install the clamp(s).

9. Inspect the toe settings again. Follow the
specifications.
End Of Sie
WM: REAR SUSPENSION
atraaw00001828
02-11–4
WHEEL ALIGNMENT
REAR WHEEL ALIGNMENT
id021100800300
Specification (Unloaded)*1
Item Specification
Tire L3: 1.0 {0.04}
(mm {in})
[Tolerance ±4 {±0.16}] AJ (3.0L Duratec): 2.6 {0.10}
Total toe-in
L3: 0°05′±0°07′
(degree)
AJ (3.0L Duratec): 0°12′±0°07′
Camber angle*2 (Reference value) 0°13′08′′ 0°10′26′′ 0°07′44′′ 0°05′06′′ 0°02′24′′
[Tolerance ±1°]
Thrust angle (Reference value) [Tolerance ±0°48′] 0°
*1 : Engine coolant and engine oil are at specified level. Spare tire, jack and tools are in designated position.
02
Rear Toe Adjustment

1. Inspect the toe setting using suitable wheel
alignment equipment.
Note
• Rock the vehicle to make sure that the
suspension is in its normal resting position.
2. Loosen the LH and RH rear suspension trailing

arm and bushing bolt.
atraaw00001829
3. Turn the LH and RH adjusting cams

simultaneously until the toe is within specification.
atraaw00001830
4. Tighten the LH and RH rear suspension trailing

arm and bushing bolts. 97.7—132.3 N·m
End Of Sie {9.97—13.49 kgf·m,
72.06—97.57 ft·lbf}
atraaw00001831
02-11–5
WHEEL AND TIRES
02-12 WHEEL AND TIRES

WHEEL AND TIRES WHEEL AND TIRE
DIAGNOSIS/TESTING . . . . . . . . . . . . . 02-12–2 REMOVAL/INSTALLATION . . . . . . . . . . 02-12–7
WHEEL AND TIRE RUNOUT . . . . . . . . . 02-12–6 WHEEL LEAKS . . . . . . . . . . . . . . . . . . . . 02-12–8
WHEEL AND TIRE SPECIFICATION . . . 02-12–7
End of Toc
WM: WHEELS AND TIRES
02
02-12–1
WHEEL AND TIRES
WHEEL AND TIRES DIAGNOSIS/TESTING
id021200800900
Inspection/Verification
Warning
• A vehicle equipped with a traction-lock differential will always have both wheels driving. If, while
the vehicle is being repaired, only one wheel is raised off the floor and the rear axle is driven by
the engine, the wheel on the floor can drive the vehicle off the stand or jack. Be sure both rear
wheels are off the floor. Failure to follow these instructions may result in personal injury.
• Never run the engine with one wheel off the ground, for example, when changing a tire. The
wheel(s) resting on the ground could cause the vehicle to move. Failure to follow these
instructions may result in personal injury.
• Do not balance the wheels and tires while they are still mounted on the vehicle. Possible tire
disintegration or differential failure can result, causing serious injury and extensive component
damage. Use off-vehicle wheel and tire balancer only. Failure to follow these instructions may
result in personal injury.
1. Be sure to follow the warnings when carrying out inspection and verification.
Road test
1. Verify the customer concern by carrying out a road test on a smooth road. If any vibrations are apparent,
diagnose the area where is attributed to NVH.
2. To maximize tire performance, inspect for signs of suspension alignment, or damaged steering incorrect
inflation and uneven wear. If there is any, indicate a need for balancing, rotation, or a suspension alignment.
3. Correct tire pressure and driving techniques have an important influence on tire life. Heavy cornering,
excessively rapid acceleration and unnecessary sharp braking increase tire wear.
4. Replacement tires should follow the recommended:
• tire sizes
• speed rating
• load range
• tire construction type
5. Use of any other tire size or type may seriously affect:
• ride
• handling
• speedometer/odometer calibration
• vehicle ground clearance
• tire clearance between the body and chassis
• wheel bearing life
• brake cooling
6. Wheels need to be replaced when:
• bent
• dented
• cracked
• heavily corroded
• leaking
• they have elongated wheel hub bolt holes
• they have excessive lateral or radial runout
7. Wheel and tire assemblies are attached by five wheel nuts.
It is mandatory to use only the tire sizes recommended on the tire chart attached to the vehicle. Larger or
smaller tires can damage the vehicle, affect road test driveability, and require changing the speedometer
calibration. Make sure wheel size and offsets match those recommended for the tire in use.
(1) Inspect for signs of uneven wear that can indicate a need for balancing, rotation, suspension alignment, or
damaged steering components.
(2) Check tires for:
• cuts
• stone bruises
• abrasions
• blisters
• embedded objects
(3) Tread wear indicators are molded into the bottom of the tread grooves. Install a new tire when the indicator
bar becomes visible.
02-12–2
WHEEL AND TIRES
Match mounting tires
1. Match mounting is a technique used to reduce radial runout. Excessive runout is a source of vibration, shimmy
and poor handling concerns. Use the following steps to reduce radial runout:
(1) Mark the wheel at the same point as the mark previously made when measuring the tire runout.
(2) Dismount the tire and remount it 180° on the wheel so the original mark on the tire is opposite the mark on
the wheel.
(3) Inflate the tire to specification.
(4) Measure the radial runout with Radial Runout Gauge at the center of the tread face. If the radial runout is
reduced to acceptable guidelines, the tire can be used. If the radial runout remains excessive, check the
wheel runout.
Tire lead diagnosis

1. Lead is the deviation of the vehicle from a straight path on a level road with no pressure on the steering wheel.
Lead can be caused by:
• incorrect wheel alignment
02
• brake drag
• incorrect/uneven tire pressure
• defective tires
2. If defective tires are suspected in a lead condition, use the following steps to determine the defective tire:
(1) Rotate the two front tires.
(2) Road test the vehicle. If the vehicle leads to the opposite direction, one of the front tires is at fault.
(3) Rotate the two front tires back to their original position.
(4) Rotate one of the front tires with its corresponding rear tire on the same side of the vehicle.
(5) Road test the vehicle. If the lead is corrected, install a new rear tire. If the lead remains, install a new front
tire on the opposite side of the vehicle.
Symptom Troubleshooting Chart

1. Verify the symptom, and conduct corresponding diagnosis.
Troubleshooting Item Possible Cause No.
Tires show excess wear on edge of • Underinflated tires 1
tread. • Vehicle overloaded
• Incorrect wheel alignment
• High-speed cornering
• Incorrect tire rotation intervals
Tires show excess wear in center of • Overinflated tires 2
tread.
Other excessive/uneven tire wear • Improper tire pressure 3
problems (Except edge and center of • Worn or damaged suspension components
tread) • Incorrect tire/wheel usage
• Damaged, loose, or leaking shock absorbers
• Incorrect wheel alignment
• Wheel and tire assembly out of balance
• Excessive lateral or radial runout of wheel or tire
• Tires need rotating
Wheel mounting is difficult. • Incorrect application or hub bolts and wheel nuts 4
• Corroded, worn or damaged new parts
Wobble or shimmy • Worn or damaged wheel bearings 5
• Loose or damaged suspension components
• Bent or damaged wheel
• Wheel and tire assembly out of balance
• Damaged tire
• Loose wheel nuts
Vehicle vibrations • Driveline. 6
• Wheel and tire assembly out of balance.
High-speed shake • Wheel hub face/pilot/bolt circle runout. 7
• Wheel and tire assembly out of balance.
• Damaged or worn wheel bearings.
• Damaged or worn suspension/steering linkage.
• Driveline.
• Brake discs/imbalance.
Damaged wheel nuts • Loose wheel assembly. 8
• Overtightened wheel nuts.
Frozen wheel nuts • Corrosion or galling. 9
• Overloading.
02-12–3
WHEEL AND TIRES
No.1 Tires Show Excess Wear On Edge Of Tread.
1 Inspect the tire pressure. Yes Go to the next step.
Is each tire pressure correct? No Adjust the tire pressure.
2 Inspect for vehicle overloading. Yes Go to the next step.
Is the vehicle under normal load? No Notify the customer of overload condition.
3 Inspect the wheel alignment. Yes Go to the next step.
Is the wheel alignment correct? No Set the alignment to specification.
4 Inspect for high-speed cornering. Yes Go to the next step.
Is there no indication of high-speed cornering? No Return vehicle — Notify the customer of cause of
condition.
5 Inspect the tire rotation interval. Yes Vehicle is normal.
Is the tire rotation interval correct? No Advise the customer of condition. Rotate tires.
No.2 Tires Show Excess Wear In Center Of Tread.

1 Inspect tire pressure. Yes Vehicle is normal.
Is the tire pressure correct? No Inspect the tire pressure.
No.3 Other Excessive (Except Edge and Center)/uneven Tire

1 Inspect the tire pressure. Yes Go to the next step.
Is the tire pressure correct? No Adjust the tire pressure.
2 Inspect wear and damage in the suspension Yes Go to the next step.
components. No Inspect according to suspension system diagnosis/
Are the suspension components normal? test.
(See 02-10-2 SUSPENSION SYSTEM DIAGNOSIS/
TESTING)
3 Inspect for correct tire and wheel usage. Yes Go to the next step.
Is the tire and wheel usage correct? No Install the correct tire and wheel combination.
4 Inspect the shock absorbers. Yes Go to the next step.
Are the shock absorbers normal? No Tighten or install new shock absorbers.
5 Inspect the wheel alignment. Yes Go to the next step.
Is the wheel alignment correct? No Set the wheel alignment to the specifications.
6 Inspect tire and wheel balance. Yes Go to the next step.
Is the tire and wheel balance correct? No Balance the wheel and tire of balance. assembly.
7 Inspect tire and wheel runout. Yes Advise the customer of the condition. Rotate the tires.
Is there any tire and wheel lateral or radial No Vehicle is normal.
runout?
No.4 Wheel Mounting Is Difficult

1 Inspect hub bolts and wheel nuts. Yes Go to the next step.
Are the hub bolts and wheel nuts correctly No Replace with correct parts.
applied and matched?
2 Inspect hub bolts and wheel nuts. Yes The vehicle is normal.
Are the hub bolts and wheel nuts normal? No Repair and replace hub bolt and wheel nut, as
necessary.
02-12–4
WHEEL AND TIRES
No.5 Wobble or Shimmy
1 Inspect wheel bearings. Yes Go to the next step.
Are the wheel bearings free of damage? No Install new wheel bearings.
2 Inspect any loose or damaged suspension Yes Go to the next step.
components. No Repair or replace suspension components, as
Are the suspension components correct? necessary.
3 Inspect the wheels. Yes Go to the next step.
Are the wheels free of damage or bending? No Replace wheels, as necessary.
4 Inspect wheel and tire balance. Yes Go to the next step.
Is the wheel and tire balance correct? No Balance the wheel and tire assembly.
5 Inspect the tires. Yes Go to the next step. 02
Are the tires free of damage? No Replace tires, as necessary.
6 Inspect wheel nuts. Yes Vehicle is normal.
Are the wheel nuts tightened securely? No Tighten to specification.
No.6 Vehicle Vibrations

1 Inspect the drive line. Yes Go to the next step.
Is the drive line normal? No Considered as a NVH concern. Repair or replace area
where attributed to NVH.
2 Inspect wheel and tire balance. Yes Vehicle is normal.
Is the wheel and tire balance correct? No Balance the wheel and tire assembly.
No.7 High Speed Shake

1. This is considered as a concern due to NVH. Identify NVH cause, and repair or replace.
No.8 Damaged Wheel Nuts

1 Inspect the wheel nuts. Yes Go to the next step.
Is the wheel nut free of looseness? No Replace wheel.
(See 02-12-7 WHEEL AND TIRE REMOVAL/
INSTALLATION.)
2 Inspect the wheel nuts. Yes Vehicle is normal.
Overtightened wheel nuts? No Remove the wheel nuts. Inspect for damage. Install
new components as necessary.
No.9 Frozen Wheel Nuts

1 Inspect for frozen wheel nuts. Yes Go to the next step.
Are the wheel nuts normal? No If the corrosion is slight, brush away the corrosion with
a wire brush. If the corrosion is excessive, install new
wheel studs and wheel nuts. If the condition persists,
lubricate the first three threads of each wheel stud with
a graphite-based lubricant
Caution
• Do not allow the lubricant to get on the cone
seats of the stud holes or on the cone angles
of the wheel nuts.
2 Inspect vehicle load condition. Yes Vehicle is normal.
Is load condition normal? No Adjust load volume, as necessary.
End Of Sie
02-12–5
WHEEL AND TIRES
WHEEL AND TIRE RUNOUT
id021200800800
1. Before inspecting runout, and to avoid false readings caused by temporary flat spots in the tires, inspect runout
only after the vehicle has been driven far enough to warm the tires.
2. Excessive radial and lateral runout of a wheel and tire assembly can cause roughness, vibration, wheel tramp,
tire wear, and steering wheel tremor.
3. The extent of the runout is measured with a radial runout gauge. All measurements are made on the vehicle
with the tires inflated to recommended inflation pressures.
Tire Runout
1. Measure radial and lateral runout at the positions
shown in the figure. Runout should not exceed
specifications.
A0005442
Wheel Runout
1. Measure radial and lateral wheel runout at the
position shown in the figure. Runout should not
exceed specifications. Note that the tire has been
removed.
End Of Sie
A0005443
02-12–6
WHEEL AND TIRES
WHEEL AND TIRE SPECIFICATION
id021200800100
Wheel and tire

Item Specification
Standard tire and wheel
Size 16 × 6 1/2J 16 × 7J
Offset (mm {in}) 50 {1.97}
Wheel
Pitch circle diameter (mm {in}) 114.3 {4.50}
Material Aluminum alloy
Size 215/70R16 99H 235/70R16 105H
Air pressure Front 210 {2.1, 30}
Tire
(kPa {bar, psi}) Rear 210 {2.1, 30}
Remaining tread (mm {in}) 1.6 {0.06}
02
Radial
1.5 {0.06} max.
Wheel and tire runout direction
Wheel and (mm {in}) Lateral
2.0 {0.08} max.
tire direction
Wheel imbalance* (g {oz}) 8 {0.28} max.
Tightening torque (N·m {kgf·m, ft·lbf}) 88.2—117.6 {9.00—11.99, 65.06—86.73}
Temporary spare tire
Size 17 × 4T 16 × 7J
Offset (mm {in}) 45 {1.77} 50 {1.97}
Wheel
Material Steel
Size T155/80R17 100M T155/90R17 101M 215/70R16 100M
Tire Air pressure
420 {4.2, 60} 250 {2.5, 36}
(kPa {bar, psi})
Radial
2.0 {0.08} max.
Wheel and Wheel and tire runout direction
tire (mm {in}) Lateral
2.5 {0.10} max.
direction
* : One balance weight: 85 g {3.00 oz} max. If the total weight exceeds 100 g {3.53 oz} on one side, rebalance
after moving the tire around on the rim. Do not use three or more balance weights.
End Of Sie
WHEEL AND TIRE REMOVAL/INSTALLATION
id021200800700
Removal
1. Loosen the wheel nuts.
2
Caution 1
• Do not use heat to loosen a seized wheel
nut. Heat can damage the wheel and
wheel bearings.
Note
• To avoid damage or scratching to the center
cap, place facing up when removed.
2
(1) If necessary, remove the center cap.
atraaw00002797
(2) With the weight of the vehicle on the wheels,
loosen the wheel nuts.
02-12–7
WHEEL AND TIRES
3. Remove the wheel and tire assembly.
(1) Remove the wheel nuts. 2 1
(2) Remove the wheel and tire assembly, using a
side-to-side rocking motion.
1
atraaw00002798
Installation
1. Clean the wheel hub mounting surface and wheel pilot.
Warning
• Whenever a wheel is installed, always remove any corrosion, dirt or foreign material present on
the mounting surfaces of the wheel or the surface of the wheel hub, brake drum or brake disc that
contacts the wheel. Installing wheels without correct metal-to-metal contact at the wheel mounting
surfaces can cause the wheel nuts to loosen and the wheel to come off while the vehicle is in
motion, causing loss of control. Failure to follow these instructions may result in personal injury.
2. Install the tire and wheel assembly.

(1) Position the tire and wheel assembly.
(2) Install the wheel nuts hand-tight, then lower the vehicle.
3. Tighten the wheel nuts in the sequence shown.
Caution
• Tighten the wheel nuts in a criss-cross
pattern. Failure to tighten this can result 1
3 4
in high brake disc runout, which will
speed up the development of brake 5 2
roughness, shudder and vibration. 88.2—117.6 N·m

{9.00—11.99 kgf·m,
4. Install the center cap. 65.06—86.73 ft·lbf}
End Of Sie
atraaw00002799
WHEEL LEAKS
id021200801000
1. Pinhole leaks in cast aluminum wheels compromise the wheel integrity. Install a new wheel.
Straightening Wheels, Rims or Components

1. Do not weld the wheels for any reason.
Note
• Do not heat wheels in an attempt to soften them for straightening to repair damage. The special alloy used
in these wheels is heat-treated. Uncontrolled heating from welding affects the properties of the material.
End Of Sie
02-12–8
FRONT SUSPENSION
02-13 FRONT SUSPENSION

FRONT SUSPENSION DUST BOOT
DIAGNOSIS/TESTING . . . . . . . . . . . . . 02-13–1 (FRONT LOWER ARM BALL JOINT)
FRONT SHOCK ABSORBER AND REMOVAL/INSTALLATION . . . . . . . . . . 02-13–6
COIL SPRING FRONT LOWER ARM BUSHING
REMOVAL/INSTALLATION. . . . . . . . . . 02-13–2 REMOVAL/INSTALLATION . . . . . . . . . . 02-13–7
FRONT SHOCK ABSORBER AND FRONT STABILIZER
COIL SPRING REMOVAL/INSTALLATION . . . . . . . . . . 02-13–8
DISASSEMBLY/ASSEMBLY . . . . . . . . . 02-13–3 STABILIZER CONTROL LINK
FRONT LOWER ARM REMOVAL/INSTALLATION . . . . . . . . . . 02-13–8
REMOVAL/INSTALLATION. . . . . . . . . . 02-13–4 FRONT CROSSMEMBER
FRONT LOWER ARM INSPECTION . . . 02-13–6 REMOVAL/INSTALLATION . . . . . . . . . . 02-13–9
02
End of Toc
FRONT SUSPENSION DIAGNOSIS/TESTING
WM: FRONT SUSPENSION
id021300801200
1. Refer to suspension system diagnosis and testing. (See 02-10-2 SUSPENSION SYSTEM DIAGNOSIS/
TESTING.)
End Of Sie
WM: FRONT SHOCK ABSORBER AND SPRING
02-13–1
FRONT SUSPENSION
FRONT SHOCK ABSORBER AND COIL SPRING REMOVAL/INSTALLATION
id021300801400
1. Remove the wheels and tires. (See 02-12-7 WHEEL AND TIRE REMOVAL/INSTALLATION.)
2. Remove the clip, them remove the brake hose
from the bracket.
atraaw00002136
3. Disconnect the ABS wheel-speed sensor wiring

harness from the shock absorber
(1) Remove the bolt. 19.1—25.9 N·m
(2) Position the bracket out of the way. 1 {1.95—2.64 kgf·m,
14.1—19.1 ft·lbf}
atraaw00002137
4. Remove the ABS wheel-speed sensor and

position out of the way.
(1) Remove the bolts.
(2) Remove the ABS wheel-speed sensor from
the steering knuckle and position out of the
way.
7.8—10.8 N·m
{80—110 kgf·cm, 69.1—95.5 in·lbf}
atraaw00002138
5. Position the stabilizer control link out of the way.

43.1—60.8 N·m
(1) Remove the nut at the top of the stabilizer {4.40—6.19 kgf·m,
control link. 1 31.8—44.8 ft·lbf}
(2) Position the stabilizer control link out of the
way. 2
atraaw00002139
02-13–2
FRONT SUSPENSION
6. Remove the bolts from the shock absorber and
steering knuckle.
93.1—116.62 N·m
{9.494—11.891 kgf·m,
68.67—86.01 ft·lbf}
atraaw00002140
7. Remove the bolts, then remove the front shock

absorber component.
72—92 N·m
{7.4—9.3 kgf·m,
02
54—67 ft·lbf}
Note
• When removing the nuts, support the shock
absorber component.

9. After installation, inspect the front wheel
alignment and adjust it if necessary. (See 02-11-2
FRONT WHEEL ALIGNMENT.)
FRONT SHOCK ABSORBER AND COIL SPRING DISASSEMBLY/ASSEMBLY

id021300801300
1. Remove the shock absorber component. (See 02-13-2 FRONT SHOCK ABSORBER AND COIL SPRING
REMOVAL/INSTALLATION.)
2. Compress the coil spring using the SST.
49 T034 1A0
Warning
• Always wear protective eyewear when
using the SST. Failure to follow these
instructions may result in personal injury.
ampjjw00000644
3. Remove the piston rod nut.
89.2—127.4 N·m
{9.10—12.99 kgf·m,
65.8—93.96 ft·lbf}
atraaw00002151
02-13–3
FRONT SUSPENSION
4. Disassemble the shock absorber and coil spring
component. 1
(1) Remove the seat.
(2) Remove the mounting rubber. 2
(3) Remove the bearing plate.
(4) Remove the bearing. 3
(5) Remove the upper spring seat.
(6) Remove the upper spring seat rubber. 4
(7) Remove the coil spring.
(8) Remove the dust boot. 5
(9) Remove the bound stopper.
(10)Remove the lower spring seat rubber. 6
Note 7
• Replace the fasteners with new ones if they
are loosened or removed.
• Always perform wheel alignment adjustment
any time the shock absorber and coil spring
or the front shock absorber mounting bracket
8
bolts are loosened. (See 02-11-2 FRONT
WHEEL ALIGNMENT.)
• Verify that the coil spring is securely seated
in the upper spring seat.
End Of Sie 9
WM: FRONT LOWER ARM
10
atraaw00002152
FRONT LOWER ARM REMOVAL/INSTALLATION

id021300800600
Removal
2. Disconnect the lower arm ball joint from the
steering knuckle.
(2) Disconnect the lower arm ball joint from the
steering knuckle.
2 1
atraaw00002153
3. Support the front crossmember.
atraaw00002154
02-13–4
FRONT SUSPENSION
4. Remove the front lower arm.
(1) Remove the front lower arm bolts.
(2) Remove the front lower arm.
atraaw00002155
Installation
02
1. Temporarily tighten the front lower arm bolts.
atraaw00002156
2. Install the bolt to the steering knuckle.
43.1—60.8 N·m
{4.40—6.19 kgf·m,
31.8—44.8 ft·lbf}
atraaw00002157
3. Remove the front crossmember support.

4. Install the wheels and tires. (See 02-12-7 WHEEL
AND TIRE REMOVAL/INSTALLATION.)
5. Rock the vehicle slightly.
atraaw00002154
02-13–5
FRONT SUSPENSION
6. Tighten the front lower arm bolts.
End Of Sie
93.1—110 N·m
{9.5—11.2 kgf·m, 68.7—81.1 ft·lbf}
133—178 N·m
{13.6—18.1 kgf·m,
99—131 ft·lbf}
atraaw00002158
FRONT LOWER ARM INSPECTION

id021300800700
1. Inspect for bending and damage.
• If there is any malfunction, replace the applicable part.
2. Inspect the ball joint for excessive play.
• If there is excessive play, replace the applicable part.
3. Rotate the ball joint stud five times and shake.
4. Install the SST to the ball joint stud.
5. Measure the rotational torque using a pull scale.
• If there is any malfunction, replace the lower
ball joint.
Rotational torque
1.47—2.94 N·m {15.0—29.9 kgf·cm, 13.1—
26.0 in·lbf}
Pull scale reading

14.7—29.4 N {1.50—2.99 kgf, 3.31—6.60
in·lbf}
aesffw00000437
End Of Sie
DUST BOOT (FRONT LOWER ARM BALL JOINT) REMOVAL/INSTALLATION
id021300801600
1. Remove the front lower arm. (See 02-13-4 FRONT LOWER ARM REMOVAL/INSTALLATION.)
2. Remove the dust boot and clean out the old grease from the ball joint.
3. Fill the inside of the new dust boot with grease.
4. Press the dust boot into the lower arm using the
SSTs and a press.
5. Wipe away any excess grease.
6. Install the front lower arm. (See 02-13-4 FRONT
LOWER ARM REMOVAL/INSTALLATION.)
End Of Sie 49 8038 785A
aesffw00000438
02-13–6
FRONT SUSPENSION
FRONT LOWER ARM BUSHING REMOVAL/INSTALLATION
id021300801700
Removal
1. Remove the front lower arm. (See 02-13-4 FRONT LOWER ARM REMOVAL/INSTALLATION.)
2. Cut off the edge of the bushing.
3. Install the SSTs as shown in the figure and
remove the bushing. 49 B034 206 49 G034 205
49 B034 204A 49 W038 002
49 U034 202
BUSHING
02
49 E034 2A0
aesffw00000439
Installation
1. Apply soapy water to the new bushing.
2. Install the SSTs as shown in the figure and install
the bushing.
3. Install the front lower arm. (See 02-13-4 FRONT
LOWER ARM REMOVAL/INSTALLATION.) 49 E034 202 49 E034 201 49 G034 205
End Of Sie
WM: FRONT STABILIZER
49 W038 002
BUSHING
49 B034 206
49 E034 2A0
aesffw00000440
02-13–7
FRONT SUSPENSION
FRONT STABILIZER REMOVAL/INSTALLATION
id021300800400
1. Remove the LH wheels and tires. (See 02-12-7 WHEEL AND TIRE REMOVAL/INSTALLATION.)
2. Remove the two stabilizer bushings.
(1) Remove the four bolts.
(2) Remove the two stabilizer bushings.
43.1—60.8 N·m 1
{4.40—6.19 kgf·m, 2
31.8—44.8 ft·lbf
atraaw00002162
3. Remove the stabilizer bar.

(1) Disconnect the stabilizer control link.
(2) Remove the stabilizer bar.
End Of Sie
WM: STABILIZER CONTROL LINK (FRONT/REAR)
2
43.1—60.8 N·m
1 {4.40—6.19 kgf·m,
31.8—44.8 ft·lbf}
atraaw00002163
STABILIZER CONTROL LINK REMOVAL/INSTALLATION

id021300801500
2. Remove the stabilizer control link.
(1) Remove the stabilizer control link nuts. 43.1—60.8 N·m 1
(2) Remove the stabilizer control link. {4.40—6.19 kgf·m,
31.8—44.8 ft·lbf}
End Of Sie
WM: FRONT CROSSMEMBER
atraaw00002217
02-13–8
FRONT SUSPENSION
FRONT CROSSMEMBER REMOVAL/INSTALLATION
id021300801000
1. Disconnect the negative battery cable. (See 01-17B-2 BATTERY REMOVAL/INSTALLATION[AJ (3.0L
Duratec)].)
2. Remove the nuts and bolts of the No. 1 engine
66.6—93.1 N·m
mount. {6.80—9.49 kgf·m, 49.2—68.6 ft·lbf}
02
atraaw00002205

then install them in the position shown in the 6.9—9.8 N·m
figure for the cylinder head (RH). {71—99 kgf·m,
62—86 ft·lbf}
Caution
303-050
(49 UN30 3050)
100—125 N·m
{10.2—12.7 kgf·m,
73.8—92.1 ft·lbf}
atraaw00003193
MAIN FRAME
REAR SHAFT
SIDE BAR
FRONT SHAFT
FRONT FOOT No.1

FRONT FOOT No.2

atraaw00002803
02-13–9
FRONT SUSPENSION
49 C017 5A0
the figure.
to the right side)
FRONT SIDE
atraaw00002804

49 C017 5A0
figure.
and horizontal.
Caution
(RH) interfere with the brake pipe, the LH
pipe.
atraaw00002805
Note 49 L017 5A0

• The SST (49E 017 5A0) can be used in
place of the SST (49C 017 5A0).
FRONT SIDE
303-050
atraaw00002806

49 C017 5A0
6. Remove the front wheels and tires.
7. Remove the front wheels and tires. (See 02-12-7
WHEEL AND TIRE REMOVAL/INSTALLATION.)
8. Remove the under cover.
49 L017 5A0
atraaw00002807
02-13–10
FRONT SUSPENSION
9. Remove the pitch bolt and nut of the front lower
arm ball joint (one each side).
43.1—60.8 N·m
{4.40—6.19 kgf·m,
31.8—44.8 ft·lbf}
atraaw00002206
10. Disconnect the stabilizer control link.

(1) Remove the nut. 02
43.1—60.8 N·m
(2) Disconnect the stabilizer control link from the {4.40—6.19 kgf·m,
stabilizer bar. 1 31.8—44.8 ft·lbf}
atraaw00002207
11. Remove the transverse member.

(1) Remove the bolts. 1
(2) Remove the transverse member. 93.1—126.4 N·m
{9.6—12.8 kgf·m,
68.7—93.2 ft·lbf}
atraaw00002208
12. Remove the No. 2 engine mount bolt.
66.6—93.1 N·m
{6.80—9.49 kgf·m,
49.2—68.6 ft·lbf}
atraaw00002209
13. Remove the engine mount member bolts.
66.6—93.1 N·m
{6.80—9.49 kgf·m,
49.2—68.6 ft·lbf}
atraaw00002210
02-13–11
FRONT SUSPENSION
14. Remove the nut, then remove the engine mount
member.
66.6—93.1 N·m
{6.80—9.49 kgf·m,
49.2—68.6 ft·lbf}
atraaw00002211
15. Remove the two steering gear bolts.

16. Disconnect the steering gear and linkage from the
crossmember. 58.8—78.4 N·m
17. Remove the front pipe (AJ (3.0L Duratec)) or the {6.00—7.99 kgf·m,
catalytic converter (L3). (See 01-15B-4 FRONT 43.4—57.8 ft·lbf}
PIPE REMOVAL/INSTALLATION[AJ (3.0L
Duratec)].) (See. 01-15A-2 EXHAUST SYSTEM
18. Remove the propeller shaft. (See 03-15-4
PROPELLER SHAFT REMOVAL/
INSTALLATION.)
19. Lower the rear of the engine approx. 150 mm
atraaw00002212
{5.91 in}.
Note
• Lower the rear of the engine to allow the crossmember to clear the companion flange on the transfer case.
20. Loosen the front two crossmember bolts but do

not remove them.
133—178 N·m
{13.6—18.1 kgf·m, 99—131 ft·lbf}
atraaw00002213
21. With another person, remove the crossmember

nuts and lower the crossmember from the vehicle. 127.5—172.5 N·m
{13.01—17.59 kgf·m,
94.1—127.2 ft·lbf}
Note
• The lower arm ball joint must be
disconnected from the steering knuckle at
the same time the crossmember is lowered.
22. Transfer necessary component parts.

End Of Sie
atraaw00002214
02-13–12
REAR SUSPENSION
02-14 REAR SUSPENSION

REAR SUSPENSION DUST BOOTS
DIAGNOSIS/TESTING . . . . . . . . . . . . . 02-14–1 (UPPER ARM AND LOWER ARM)
REAR SHOCK ABSORBER REMOVAL/INSTALLATION . . . . . . . . . . 02-14–3
REMOVAL/INSTALLATION. . . . . . . . . . 02-14–1 REAR UPPER ARM
REAR COIL SPRING REMOVAL/ INSTALLATION . . . . . . . . . . 02-14–4
REMOVAL/ INSTALLATION . . . . . . . . . 02-14–2 REAR CROSSMEMBER
REAR LOWER ARM REMOVAL/INSTALLATION . . . . . . . . . . 02-14–5
REMOVAL/INSTALLATION. . . . . . . . . . 02-14–3
End of Toc
REAR SUSPENSION DIAGNOSIS/TESTING
02
WM: REAR SUSPENSION
id021400801600
1. Refer to suspension system diagnosis and testing. (See 02-10-2 SUSPENSION SYSTEM DIAGNOSIS/
TESTING.)
End Of Sie
REAR SHOCK ABSORBER REMOVAL/INSTALLATION
WM: REAR SHOCK ABSORBER
id021400801300
1. Remove the upper shock absorber nut.
(1) Remove the rear quarter trim panel and upper
shock absorber nut.
2. Raise and support the vehicle enough to relax the
suspension system.
12.6—17.0 N·m
{129—173 kgf·cm,
112—150 in·lbf}
atraaw00002224
3. Remove the shock absorber.

(1) Remove the lower shock absorber nut.
(2) Remove the shock absorber.
End Of Sie
WM: REAR COIL SPRING
97.7—132.3 N·m
{9.97—13.49 kgf·m,
72.06—97.57 ft·lbf}
atraaw00002225
02-14–1
REAR SUSPENSION
REAR COIL SPRING REMOVAL/ INSTALLATION
id021400801700
1. Remove the wheel and tire assembly. (See 02-12-7 WHEEL AND TIRE REMOVAL/INSTALLATION.)
2. Remove the brake pipe fixing clip, and disconnect the brake pipe.
3. Position the ABS wheel-speed sensor aside. 7.6—10.4 N·m
(1) Remove the ABS wheel-speed sensor bolt {78—106 kgf·cm,
and bracket bolts. 67.3—92.0 in·lbf} 1
(2) Position the ABS wheel-speed sensor aside.
4. Support the rear wheel knuckle.
atraaw00002228
5. Loosen both inside upper and lower arm bolts.

97.7—132.3 N·m
{9.97—13.49 kgf·m,
72.06—97.57 ft·lbf}
atraaw00002229
6. Remove the lower shock nut and position aside.
97.7—132.3 N·m
{9.97—13.49 kgf·m,
72.06—97.57 ft·lbf}
atraaw00002230
7. Remove the spring.
Note
• Note the position of the upper spring seat
rubber and spring for installation.
(1) Remove the support to the wheel knuckle.

(2) Remove the spring.
8. Remove in the reverse order of removal.
9. Bleed the brake system after installation. (See 04-
11-2 AIR BLEEDING (BRAKE SYSTEM).)
End Of Sie
WM: REAR LOWER ARM atraaw00002231
02-14–2
REAR SUSPENSION
REAR LOWER ARM REMOVAL/INSTALLATION
id021400800900
2. Separate the lower ball joint from the knuckle.
(1) Remove the lower ball joint nut.
Note
• It may be necessary to hold the ball joint
stud to keep it from turning while removing
the nut.
97.7—132.3 N·m
{9.97—13.49 kgf·m,
72.06—97.57 ft·lbf}
atraaw00002237
02
3. Remove the lower arm.
(1) Remove the lower arm inner bolt. 97.7—132.3 N·m
(2) Remove the lower arm. {9.97—13.49 kgf·m,
72.06—97.57 ft·lbf} 1
End Of Sie
atraaw00002238
DUST BOOTS (UPPER ARM AND LOWER ARM) REMOVAL/INSTALLATION

id021400801900
1. Remove the upper arm or lower arm. (See 02-14-3 REAR LOWER ARM REMOVAL/INSTALLATION.) (See 02-
14-4 REAR UPPER ARM REMOVAL/ INSTALLATION.)
2. Remove the ball joint dust boot.
Caution
• Avoid any damage to the ball pin while
removing the old boot. AVOID BETTING
GREASE
THESE PORTIONS
3. Wipe old grease off the ball pin, then apply new GREASED
grease to the ball pin-housing contact portion.
4. Apply new grease inside the new dust boot and to
the lip.
Caution
• Avoid greasing the ball pin tapered
aesffw00000442
portion and boot contact portion.

• Avoid getting any objects other than new grease into the boot.
• Avoid greasing the threaded portion of the ball pin during the new dust boot installation.
02-14–3
REAR SUSPENSION
5. Install a new dust boot using the SST. UPPER ARM PRESS
49 E028 302
USE MARKED "U" SIDE
DO NOT SUPPORT
THE END COVER
aesffw00000443
LOWER ARM PRESS

Caution
• Do not press or support the end cover of
the housing.
• Wipe away excess grease. 49 E028 302
6. Inspect for any damage or deformation of the dust USE MARKED "L" SIDE
boot and any gap between the housing and the
dust boot bottom flange.
End Of Sie
WM: REAR UPPER ARM
DO NOT SUPPORT
THE END COVER
aesffw00000444
REAR UPPER ARM REMOVAL/ INSTALLATION

id021400801800
2. Separate the upper arm from the wheel knuckle.
(1) Remove the upper ball joint nut.
Note
• It may be necessary to hold the ball joint
stud to keep it from turning while removing
the nut.
97.7—132.3 N·m
{9.97—13.49 kgf·m,
72.06—97.57 ft·lbf}
atraaw00002239
3. Remove the upper arm. 97.7—132.3 N·m

(1) Remove the upper arm inner bolt. {9.97—13.49 kgf·m, 1 2
(2) Remove the upper arm. 72.06—97.57 ft·lbf}
4. Remove in the reverse order of removal.
End Of Sie
WM: REAR CROSSMEMBER
atraaw00002240
02-14–4
REAR SUSPENSION
REAR CROSSMEMBER REMOVAL/INSTALLATION
id021400801000
Removal
2. Remove the rear differential. (See 03-14-1 REAR DIFFERENTIAL REMOVAL/INSTALLATION.)
3. Remove the four bolts and disconnect the upper
and lower arm from rear crossmember.
02
atraaw00002415
4. Disconnect the exhaust hanger from the rear

crossmember.
atraaw00002416
5. With another person, remove the rear

crossmember.
atraaw00002417
Installation
1. With another person, temporarily install the rear
crossmember.
atraaw00002417
02-14–5
REAR SUSPENSION
2. With a 19 mm {0.75 in} rod, align the rear
crossmember with the alignment holes.
atraaw00002418
3. Tighten the rear crossmember bolts.

97.7—132.3 N·m
{9.97—13.49 kgf·m,
72.06—97.57 ft·lbf}
atraaw00002419
4. Connect the exhaust hanger to the rear

crossmember.
atraaw00002420
5. Position the four rear control arms in the rear

crossmember.
(1) Temporarily tighten the bolts.
6. Install the rear differential. (See 03-14-1 REAR
DIFFERENTIAL REMOVAL/INSTALLATION.)
atraaw00002421
8. Tighten the four control arms bolts.
Note
• The vehicles must be on the ground before
tightening the bolts.
97.7—132.3 N·m
{9.97—13.49 kgf·m,
End Of Sie 72.06—97.57 ft·lbf}
atraaw00002422
02-14–6
TECHNICAL DATA
02-50 TECHNICAL DATA

SUSPENSION TECHNICAL DATA . . . . . 02-50–1
End of Toc
SUSPENSION TECHNICAL DATA
WM: SUSPENSION
id025000800100
Item Specification
Maximum 215/70R16 Inner 37°06′
steering tires Outer 30°54′
angle
[Tolerance 235/70R16 Inner 35°18′
±3°] tires Outer 29°48′ 02
Tire
L3: –1.0 {0.04}
[Tolerance ±4 (mm {in})
AJ (3.0L Duratec): 3.0 {0.12}
Front wheel Total {±0.16}]
alignment toe-in
L3: –0°05′±0°14′
(degree)
(Unloaded)*1 AJ (3.0L Duratec): 0°14′±0°14′
Caster angle*2 1°47′24′′
[Tolerance ±1°]
Camber angle*2 L3: –0°28′48′′
[Tolerance ±1°] AJ (3.0L Duratec): –0°50′24′′
Steering axis inclination L3: 11°06′
(Reference value) AJ (3.0L Duratec): 11°24′
Tire
L3: 1.0 {0.04}
[Tolerance ±4 (mm {in})
Total AJ (3.0L Duratec): 2.6 {0.10}
{±0.16}]
toe-in
Rear wheel L3: 0°05′±0°07′
(degree)
alignment AJ (3.0L Duratec): 0°12′±0°07′
(Unloaded)*1 Camber angle*2 (Reference value)
0°13′08′′ 0°10′26′′ 0°07′44′′ 0°05′06′′ 0°02′24′′
[Tolerance ±1°]
Thrust angle (Reference value)
0°
[Tolerance ±0°48′]
Front lower arm ball joint rotation torque 1.47—2.94 {15.0—29.9, 13.1—26.0}
(N·m {kgf·cm, in·lbf}) {Pull scale reading: 14.7—29.4 N (1.50—2.99 kgf, 3.31—6.60 lbf)}
*1
: Engine coolant and engine oil are at specified level. Spare tire, jack, and tools are in designated position.
Adjust to the median when carrying out wheel alignment.
02-50–1
TECHNICAL DATA
Wheel and tire
Item Specification
Standard tire and wheel
Size 16 ×6 1/2J 16 × 7J
Offset (mm {in}) 50 {1.97}
Wheel
Material Aluminum alloy
Size 215/70R16 99H 235/70R16 105H
Air pressure Front 210 {2.1, 30}
Tire
(kPa {bar, psi}) Rear 210 {2.1, 30}
Remaining tread (mm {in}) 1.6 {0.06}
Radial
1.5 {0.06} max.
Wheel and tire runout direction
Wheel and (mm {in}) Lateral
2.0 {0.08} max.
tire direction
Wheel imbalance* (g {oz}) 8 {0.28} max.
Tightening torque (N·m {kgf·m, ft·lbf}) 88.2—117.6 {9.00—11.99, 65.06—86.73}
Temporary spare tire
Size 17 × 4T 16 × 7J
Offset (mm {in}) 45 {1.77} 50 {1.97}
Wheel
Material Steel
Size T155/80R17 100M T155/90R17 101M 215/70R16 100M
Tire Air pressure
420 {4.2, 60} 250 {2.5, 36}
(kPa {bar, psi})
Radial
2.0 {0.08} max.
Wheel and Wheel and tire runout direction
tire (mm {in}) Lateral
2.5 {0.10} max.
direction
* : One balance weight: 85 g {3.00 oz} max. If the total weight exceeds 100 g {3.53 oz} on one side, rebalance
after moving the tire around on the rim. Do not use 3 or more balance weights.
End Of Sie
02-50–2
SERVICE TOOLS
02-60 SERVICE TOOLS

SUSPENSION SST . . . . . . . . . . . . . . . . . 02-60–1
End of Toc
SUSPENSION SST
WM: SUSPENSION
id026000800100
1: Mazda SST number
2: Global SST number
Example
1:49 UN30 3050
2:303-050
Engine lifting 02
brackets
1:49 0180 510B 1:49 8038 785A 1:49 E034 2A0

2: — 2: — 2: —
Preload Dust boot Rubber bushing

measuring installer replacer set
attachment
1:49 T034 1A0 1:49 E028 302 1: 49 C017 5A0*

2: — 2: — 2: –
Coil spring Dust boot Engine support
compressor set installer set
1:49 L017 5A0 1:49 UN30 3050

2: — 2:303-050
Support hanger
Engine lifting
brackets —
* : The SST (49 E017 5A0) can be used in place of the SST (49 C017 5A0).
End Of Sie
02-60–1
DRIVELINE/AXLE 03
SECTION
Toc of SCT
SYMPTOM PROPELLER SHAFT . . . . . . . . 03-15
TROUBLESHOOTING . . . . . . 03-03 TRANSFER[GF4AX-EL]. . . . . . 03-16A
GENERAL PROCEDURES . . . 03-10 TRANSFER
FRONT AXLE. . . . . . . . . . . . . . 03-11 [LA4AX-EL (CD4E)] . . . . . . . . 03-16B
REAR AXLE. . . . . . . . . . . . . . . 03-12 4-WHEEL DRIVE . . . . . . . . . . . 03-18
DRIVE SHAFT . . . . . . . . . . . . . 03-13 TECHNICAL DATA . . . . . . . . . . 03-50
DIFFERENTIAL . . . . . . . . . . . . 03-14 SERVICE TOOLS . . . . . . . . . . . 03-60
Toc of SCT
03-03 SYMPTOM TROUBLESHOOTING
SYMPTOM TROUBLESHOOTING No.3 FRONT WHEELS SLIP
CHART. . . . . . . . . . . . . . . . . . . . . . . . . . 03-03–1 FREQUENTLY . . . . . . . . . . . . . . . . . . . . 03-03–3 03
No.1 4x4 LOCK INDICATOR LIGHT No.4 RBC UNIT GENERATES
ILLUMINATED CONTINUOUSLY ABNORMAL NOISE OR
(4x4 SYSTEM OPERATES VIBRATION. . . . . . . . . . . . . . . . . . . . . . . 03-03–4
NORMALLY) . . . . . . . . . . . . . . . . . . . . . 03-03–2 No.5 TIGHT-CORNER BRAKING
No.2 MODE CHANGE BETWEEN AUTO PHENOMENON OCCURS . . . . . . . . . . . 03-03–5
AND 4x4 ON IS NOT PERFORMED
NORMALLY . . . . . . . . . . . . . . . . . . . . . . 03-03–2
End of Toc
SYMPTOM TROUBLESHOOTING CHART
WM: ELECTRONIC 4WD CONTROL SYSTEM
id030300801200
• Verify the symptom, and perform the corresponding malfunction diagnosis.
• Some malfunction diagnosis procedures require performing inspection/verification while the malfunction is
occurring. Always perform these procedures while verifying the symptom.
No. Troubleshooting Item
1 4×4 lock indicator light illuminated continuously (4×4 system operates normally)
2 Mode change between AUTO and 4×4 ON is not performed normally
3 Front wheels slip frequently
4 RBC unit generates abnormal noise or vibration
5 Tight-corner braking phenomenon occurs
End Of Sie
03-03–1
SYMPTOM TROUBLESHOOTING
No.1 4x4 LOCK INDICATOR LIGHT ILLUMINATED CONTINUOUSLY (4x4 SYSTEM OPERATES NORMALLY)
id030300801300
Possible Cause
• Malfunction in the 4×4 lock indicator light control circuit
— 4×4 lock switch malfunction
— Instrument cluster malfunction
— Short to power supply in 4×4 lock indicator light wiring harness
— Short to power supply in 4×4 lock switch wiring harness
Diagnostic Procedure
1 INSPECT 4×4 SWITCH Yes Go to the next step.
• Inspect the 4×4 lock switch. No Replace the 4×4 lock switch.
• Is the 4×4 lock switch normal?
2 INSPECT 4×4 LOCK INDICATOR LIGHT Yes • Inspect the instrument cluster. (See 09-22-4
WIRING HARNESS FOR SHORT TO POWER INSTRUMENT CLUSTER INSPECTION.)
SUPPLY • If there is any malfunction, repair or replace the
• Turn the ignition switch off. applicable part.
• Disconnect the 4×4 lock switch connector. No Repair or replace the wiring harness between 4×4 lock
• Turn the ignition switch to the ON position. switch terminal B and instrument cluster terminal 1A.
• Measure the voltage between the 4×4 lock
switch vehicle-side terminal B and ground.
• Is the voltage less than 1.0 V?
End Of Sie
No.2 MODE CHANGE BETWEEN AUTO AND 4x4 ON IS NOT PERFORMED NORMALLY
id030300801400
Possible Cause
• 4×4 lock switch malfunction
• 4×4 lock solenoid sticking
• RBC unit malfunction
1 INSPECT 4×4 LOCK SYSTEM FOR POWER Yes Go to the next step.
SUPPLY No Repair or replace the malfunctioning part.
• Turn the ignition switch off.
• Disconnect the 4×4 lock switch connector.
• Turn the ignition switch to the ON position.
• Measure the voltage at terminal B of the 4×4
lock switch vehicle-side connector.
• Is the voltage 10 V or more?
2 INSPECT 4×4 LOCK SWITCH Yes Go to the next step.
• Inspect the 4×4 lock switch. No Replace the 4×4 lock switch.
• Is the 4×4 lock switch normal?
3 INSPECT 4×4 RELAY COIL SIDE POWER Yes Go to the next step.
SUPPLY WIRING HARNESS FOR OPEN No Repair or replace the wiring harness between 4×4 lock
CIRCUIT switch terminal A and 4×4 relay terminal A.
• Connect the 4×4 lock switch.
• Disconnect the 4×4 relay connector.
• Set the 4×4 lock switch ON (LOCK).
• Measure the voltage at terminal A of the 4×4
relay vehicle-side connector.
4 INSPECT 4×4 RELAY COIL SIDE GROUND Yes Go to the next step.
WIRING HARNESS FOR OPEN CIRCUIT No Repair or replace any malfunction.
• Measure the resistance between terminal B
of the 4×4 relay vehicle-side connector and
body ground.
• Is the resistance less than 5 ohms?
03-03–2
5 INSPECT 4×4 RELAY SWITCH SIDE GROUND Yes Go to the next step.
WIRING HARNESS FOR OPEN CIRCUIT No Repair or replace the wiring harness between CJB
• Turn the ignition switch off. terminal B and 4×4 relay terminal D.
• Measure the voltage between terminal D of
the 4×4 relay vehicle-side connector and
body ground.
6 INSPECT 4×4 RELAY Yes Go to the next step.
• Inspect the 4×4 relay. No Replace the 4×4 relay.
• Is the 4×4 relay normal?
7 INSPECT 4×4 LOCK SOLENOID POWER Yes Go to the next step.
SUPPLY SYSTEM WIRING HARNESS FOR No Repair or replace any malfunction.
OPEN CIRCUIT
• Disconnect the 4×4 lock solenoid connector.
• Measure the resistance between terminal C
of the 4×4 relay vehicle-side connector and
terminal B of the 4×4 lock solenoid vehicle-
side wiring harness. 03
8 INSPECT 4×4 LOCK SOLENOID GROUND Yes Go to the next step.
WIRING HARNESS FOR OPEN CIRCUIT No Repair or replace any malfunctioning.
• Measure the resistance between terminal A
of the 4×4 lock solenoid vehicle-side
connector and ground.
9 INSPECT CONNECTORS FOR CONNECTION Yes Repair or replace any malfunction.
• Turn the ignition switch off. No Replace the RBC unit.
• Inspect the pin connection of the following
connectors.
— 4×4 lock switch
— 4×4 relay
— 4×4 lock solenoid
• Is there any poor connection or corrosion?
End Of Sie
No.3 FRONT WHEELS SLIP FREQUENTLY
id030300800900
Possible Cause
• The traction performance of the tire is too low for engine power and road surface friction coefficients (4×4
system is normal)
• The following cause is suspected if the front wheels slip frequently in 4×4 lock mode (the wheels slip as
frequently as in 4×4 AUTO mode).
— 4×4 lock solenoid is inoperative.
• The wheel alignment is not adjusted correctly (4×4 system is normal)
• Excessive tire wear (4×4 system is normal)
Warning
• When performing the driving test, vehicle stability may be lost suddenly. Perform the driving test
in safe surroundings to avoid any unexpected accident.

1 INSPECT FOR OTHER MALFUNCTIONS Yes Go to the applicable diagnostic procedure.
• Is there any other malfunction listed in the No Go to the next step.
symptom troubleshooting chart?
2 VERIFY THE MALFUNCTION Yes Go to the next step.
• Compare the frequency of front wheel slip No Perform the diagnostic procedure “No.2 MODE
between 4×4 lock mode and 4×4 AUTO CHANGE BETWEEN AUTO AND 4×4 ON IS NOT
mode. PERFORMED NORMALLY”.
• Is there any difference in the slip frequency?
03-03–3
3 VERIFY TIRE PRESSURE Yes Go to the next step.
• Verify the tire pressure. No Adjust the tire pressure and go to the next step.
• Is tire pressure within the specification?
4 COMPARE WITH OTHER VEHICLE’S TIRES Yes Go to the next step.
• Install the tires of the compared vehicle to No The 4×4 system is normal. (The tires are the suspected
the malfunctioning vehicle. cause)
• Perform the driving test.
• Is there any malfunction?
5 COMPARE WITH OTHER VEHICLE Yes The 4×4 system is normal. (The tires are the suspected
• Install the tires of the malfunctioning vehicle cause)
to the compared vehicle. No Go to the next step.
• Perform the driving test.
• Is there any malfunction?
6 VERIFY WHEEL ALIGNMENT Yes Replace the RBC unit.
• Verify the wheel alignment. No Adjust the wheel alignment.
• Is the wheel alignment within the
specification?
End Of Sie
No.4 RBC UNIT GENERATES ABNORMAL NOISE OR VIBRATION
id030300801000
Possible Cause
• The 4×4 lock system is designed to improve driveability on snow covered roads and to free a stuck vehicle.
Abnormal noise or vibration may occur while turning on a dry surface with the 4×4 lock on.
• RBC unit generates an abnormal noise or vibration while driving
• Propeller shaft malfunction or improper installation
• Engine mount, differential mount malfunction
• If the malfunction occurs at a certain vehicle speed or engine speed, resonance caused by the rotating parts of
the vehicle, such as engine, propeller shaft, rear differential, and tires, may be the cause.
• Resonance caused by engine vibration (mainly exhaust system)
• Resonance caused by rear differential
1 INSPECT PARTS FOR IMPROPER Yes Repair or replace any malfunction.
INSTALLATION No Go to the next step.
• Inspect the following parts for improper
installation.
— Propeller shaft (including bending and
joint parts operation)
— Center bearing
— Engine mount
— Differential mount
— Hub bearing
— Exhaust system parts
— ABS wheel-speed sensor rotor
• Is the malfunction verified?
2 INSPECT FOR REAR DIFFERENTIAL Yes The 4×4 system is normal. (Resonance caused by the
MALFUNCTION vehicle rotating parts)
• Install a different brand of tires. No Install the original tires and go to the next step.
Caution
• When a different brand of tires are
installed, the same malfunction
may occur under different
conditions (engine and vehicle
speed). Do not confuse this with the
malfunction which the customer
indicated.
• Drive the vehicle under the same conditions

(engine speed, gear position, vehicle speed,
and accelerator opening angle) which the
customer indicated.
• Is the level of the malfunction reduced?
03-03–4
3 INSPECT REAR DIFFERENTIAL Yes Replace the RBC unit.
• Inspect the rear differential for the following. No Inspect and adjust any malfunction.
— Backlash
— Tooth meshing
(See 03-14-2 REAR DIFFERENTIAL
DISASSEMBLY/ASSEMBLY.)
• Are the results normal?
End Of Sie
No.5 TIGHT-CORNER BRAKING PHENOMENON OCCURS
id030300801100
Possible Cause
• The 4×4 lock system is designed to improve driveability on snow covered roads and free a stuck vehicle.
Abnormal noise or vibration may occur while turning on a dry surface with the 4×4 lock on.
• 4×4 lock solenoid malfunction (sticking in 4×4 lock)
• The difference in front and rear wheel rotation cannot be absorbed due to a high locking rate of the RBC unit
(close to that of 4×4 lock) and this causes a braking phenomenon.
• Tight-corner braking phenomenon occurs while turning sharply on a dry surface because of the RBC unit
construction. (Verify that the 4×4 system is normal by comparing with another vehicle.) 03
1 INSPECT TIRE PRESSURE Yes Go to the next step.
• Inspect the tire pressure. No Adjust the tire pressure to the specification and drive
• Is the tire pressure normal? the vehicle. If the malfunction is verified, go to the next
step.
2 COMPARE WITH ANOTHER VEHICLE Yes The 4×4 system is normal.
• Perform the driving test with another vehicle. No Go to the next step.
• Does the malfunction occur in another
vehicle?
3 INSPECT 4×4 LOCK SOLENOID Yes Perform the diagnostic procedure “No.2 MODE
• Inspect the 4×4 lock solenoid. CHANGE BETWEEN AUTO AND 4×4 ON IS NOT
• Is the 4×4 lock solenoid normal? PERFORMED NORMALLY”.
No Replace the RBC unit.
End Of Sie
03-03–5
GENERAL PROCEDURES
03-10 GENERAL PROCEDURES

DRIVELINE SYSTEM
DIAGNOSIS/TESTING . . . . . . . . . . . . . 03-10–2
End of Toc
WM: DRIVELINE/AXLE
03
03-10–1
GENERAL PROCEDURES
DRIVELINE SYSTEM DIAGNOSIS/TESTING
id031000800200
Inspection/Verification
1. Certain axle and driveline malfunction symptoms are also common to the engine, transaxle, wheel bearings,
tires, and other parts of the vehicle. For this reason, be sure that the cause of the malfunction is in the axle
before adjusting, repairing, or installing any new parts.
Propeller shaft center universal joint (U-Joint) and constant velocity (CV) joint inspection
1. Lift up the vehicle on a frame hoist and rotate the propeller shaft by hand. Inspect for rough operation or seizure
of the U-joint. Inspect for rough operation of the U-joint and sticking of the U-joint and the CV-joint. Install a new
propeller shaft if it shows signs of sticking, excessive wear, or incorrect installation. (See 03-15-4 PROPELLER
SHAFT REMOVAL/INSTALLATION.)
Propeller shaft center bearing

1. Rotate the propeller shaft by hand. If the bearing shows signs of roughness or is noisy, install a new propeller
shaft. (See 03-15-4 PROPELLER SHAFT REMOVAL/INSTALLATION.)
Noise acceptability
1. A gear-driven unit will produce a certain amount of noise. Some noise is acceptable and audible at certain
speeds or under various driving conditions such as a newly paved blacktop road. Slight noise is not detrimental
to the operation of the axle and is considered normal.
Preliminary diagnosis
Question the customer
• The preliminary diagnosis starts with the customer interview about the history of the concern. When did the
customer notice the symptom first? Did the symptom appear suddenly or gradually? Did any abnormal
occurrence coincide with or precede its appearance (such as pothole or curb impacts, small collisions, or
similar occurrence.)? Were any repair procedures performed or new parts installed? It is also necessary to
know any special conditions affecting the appearance and degree of the concern, such as vehicle speed, type
of road, drive mode, engine temperature, or ambient temperature.
• A gradual appearance of the concern indicates a deterioration of a component, such as tires, propeller shaft or
wheel bearings.
• A sudden appearance of the concern could indicate a lost wheel balance weight or sticking of the CV joint.
Road test
• A road test is mandatory for any customer concern of noise/vibration that is not verified by the on-hoist check of
chassis components. The road test form is arranged to record the conditions heard or felt during this test.
• The road test form lists four operating conditions or modes in which some axle noises come and go: DRIVE,
CRUISE, COAST, and FLOAT.
Mode Conditions
DRIVE Accelerating the vehicle: a definite throttle depression applying engine torque.
CRUISE Maintaining a constant speed with the throttle applied.
COAST Decelerating with the throttle closed.
FLOAT Controlled deceleration: gradually backing off the throttle to prevent either braking or accelerating torque
from the engine.
03-10–2
GENERAL PROCEDURES
• Operate the vehicle in all four modes and record those in which the noise occurs. Record the km/h range at
which both noise and vibration occur. If equipped with four-wheel four-drive (4×4), rear axle evaluations should
be done on straight road sections only with 4×4 lock engaged. The transfer case has similar construction to the
rear differential. Both components exhibit similar noise characteristics. Axle noise can originate from either the
transfer case or the rear differential. Evaluate the vehicle between 100—130 km/h {60—80 mph}. The transfer
case will have objectionable noise frequency 600 Hz or above. Rear differential will have objectionable noise
frequency 600 Hz or below.
VEHICLE ROAD TEST EVALUATION

Road Test Evaluations:
1. Does the problem occur with engine, driveshaft, or wheel speed?
Engine
Driveshaft
Wheel
2. Is the problem road speed dependent? (Occurs at the same vehicle speed
independent of transmission gear).
03
Yes
No
3. Is the problem engine speed dependent? (Occurs at the same engine rpm,
independent of transmission gear).
Yes
No
4. If the problem is engine speed dependent, perform a neutral engine runup (NERU),
and compare rpm’s to road rpm’s.
Same as NERU
Different than NERU
5. Is the problem drive mode dependent? (Occurs in drive, cruise, coast/float).
Drive Speed
Cruise Speed
Coast Speed
Float Speed
6. Is the problem acceleration rate dependent? (Light, medium or heavy throttle).
Light
Medium
Heavy
7. Does the problem occur from a stop?
Yes
No
8. Is the problem transmission gear dependent? (Occurs in overdrive, but not
direct drive).
Yes
No
9. Does the problem occur on turns?
Yes
No
10. Does the problem only occur when going from reverse to drive or drive to reverse?
Yes
No
aesffw00000351
Analysis of leakage
1. Clean up the leaking area enough to identify the exact cause.
2. A plugged axle housing vent can cause excessive pinion seal lip wear due to internal pressure buildup.
03-10–3
GENERAL PROCEDURES
Axle vent
1. A plugged vent will cause excessive seal lip wear due to internal pressure buildup. If a leakage occurs, inspect
the vent. If the vent cannot be cleared, install a new vent.
Flange yoke seal

1. Leakage at the axle drive pinion seal originates for the following reasons:
• Damaged seal
• Worn seal journal surface
2. Any damage to the seal bore (dings, dents, gouges, or other imperfections) will distort the seal casing and allow
leakage past the outer edge of the axle drive pinion seal.
3. The axle drive pinion seal can be torn, cut, or gouged if it is not installed carefully. The spring that holds the axle
drive pinion seal against the pinion flange may be removed and allow leakage past the lip.
4. A new pinion flange must be installed if any of these conditions exist.
5. Metal chips trapped at the sealing lip can cause oil leakage. These can cause a wear groove on the pinion
flange and pinion seal wear.
6. When seal leakage occurs, install a new seal and inspect the vent to verify that it is clean and free of foreign
material.
Drive pinion nut
Caution
• Tighten the nuts to the specified torque.
1. On some high-mileage units, oil may leak past the threads of the pinion nut. This condition can be corrected by
installing a new nut and applying threadlock and sealer on the threads and nut face.
Differential seals
Caution
• When installing shafts, do not allow splines to contact seal during installation.
1. The propeller shaft pilot bearing housing seals are susceptible to the same kinds of damage as the axle drive
pinion seals if incorrectly installed. The seal bore must be clean and the lip handled carefully to avoid cutting or
tearing it. The seal journal surface must be free of nicks, gouges, and rough surface texture.
Analysis of vibration
1. Few vibration conditions are caused by the rear axle. When vibration occurs, and if an obvious reason, which
indicates the vibration is caused by axle, is not detected, a malfunction caused by NVH is suspected. Detect
the part which causes NVH and repair or replace it.
Tire
Caution
• Do not balance the wheels and tires while they are still mounted on the vehicle. Possible tire
disintegration or differential/propeller shaft failure can result, causing personal injury and
extensive component damage. Remove the wheels from the vehicle, and use an off-vehicle wheel
and tire balancer only.
1. Most vibration in the rear end is caused by tires.

2. Vibration is a concern with tires if they are not in correct condition both radially and laterally. Tires are more
susceptible to vibration around the limits of radial and lateral runout of the tire and wheel components. In this
case, more accurate balancing is required. Wheel and tire runout inspection, and adjustment and balancing are
normally done before axle inspection.
03-10–4
GENERAL PROCEDURES
Wheel hub flange bolt circle runout
Note
• The brake discs must be removed to perform all runout measurements.
1. Install a commercially-available tool perpendicular to the wheel hub bolt, as close to the hub face as possible.
Set the indicator to zero to allow the pointer to deflect either way.
2. Rotate the hub until the next bolt is contacted.
Record the measurement and continue until each
COMMERCIALLY-
bolt has been inspected. The difference between
AVAILABLE TOOL
the maximum and minimum contact readings will
be the total wheel hub bolt pattern runout. The
runout must not exceed 0.38 mm {0.015 in}.
03
aesffw00000352
Pilot runout
1. Install commercially-available tools as close to the hub face as possible. Set the indicator to zero to allow the
pointer to deflect either way.
2. Rotate the hub one full turn and note the
maximum and minimum readings. The difference
between the maximum and minimum readings will
be the total pilot runout. Pilot runout must not
exceed 0.15 mm {0.006 in}.
COMMERCIALLY-
AVAILABLE TOOL
COMMERCIALLY-
AVAILABLE TOOL
aesffw00000353
Wheel hub face runout

1. Install a commercially-available tool on the wheel hub face, as close to the outer edge as possible. Set the
indicator to zero to allow the pointer to deflect either way.
2. Rotate the hub one full turn and note the
maximum and minimum readings. The difference COMMERCIALLY-
between the maximum and minimum readings will AVAILABLE TOOL
be the total face runout. The runout must not
exceed 0.254 mm {0.010 in}.
aesffw00000354
03-10–5
GENERAL PROCEDURES
Rear drive shaft
Note
• Install new CV joints only if disassembly and inspection reveals unusual wear. Refer to the section 03-13.
• While inspecting the boots, inspect for indentations in the boot bellows. Indentations must be removed.
• Inspect the boots for cracks, tears, or splits.

• Inspect the underbody for any indication of grease splatter near the boots outboard and inboard locations. This
is an indication of boot/clamp damage.
Component Tests
Driveline vibration
1. Driveline vibration exhibits a higher frequency and lower amplitude than does high-speed shake. Driveline
vibration is directly related to the speed of the vehicle and is usually noticed at various speed ranges. Driveline
vibration can be perceived as a tremor in the floorpan or is heard as a rumble, hum, or boom. Driveline vibration
can exist in all drive modes, but may exhibit different symptoms depending upon whether the vehicle is
accelerating, decelerating, floating, or coasting. Inspect the driveline angles if the vibration is particularly
noticeable during acceleration or deceleration, especially at lower speeds. Driveline vibration can be duplicated
on the lift or the jack stands. When performing test on the lift, the suspension lower arms must be supported
with jack stands to make sure the drive shaft maintain the correct ride height. The brakes may need to be
applied lightly in order to simulate road resistance.
End Of Sie
03-10–6
FRONT AXLE
03-11 FRONT AXLE

WHEEL HUB, STEERING KNUCKLE WHEEL HUB BOLT
INSPECTION . . . . . . . . . . . . . . . . . . . . . 03-11–1 REMOVAL/INSTALLATION . . . . . . . . . . 03-11–6
WHEEL HUB, STEERING KNUCKLE
End of Toc
WHEEL HUB, STEERING KNUCKLE INSPECTION
WM: FRONT AXLE
id031100800300
Wheel Bearing Excessive Play Inspection
1. Raise the vehicle until the front tires are off the
floor.
• Verify that the wheels are in the straight-
ahead position.
2. Rotate the tire by hand and inspect the wheel
bearings for roughness.
Note 03
• Verify that the wheel rotates freely and that
the brake pads are retracted sufficiently to
allow free movement of the tire and wheel
component.
aesffw00000448
3. Grip each front tire at the top and bottom and

move the wheel inward and outward while lifting
the weight of the tire off the front wheel bearing.
aesffw00000449
4. If the tire and wheel (hub) is loose on the spindle,

does not rotate freely, or has a rough feeling when
spun, perform one of the following: 1
• On vehicles with inner and outer bearings,
inspect the bearings and cups for wear or
damage. Adjust or install new bearing and
cups if necessary.
• On vehicles with one sealed bearing, install a
new wheel hub. (See 03-11-2 WHEEL HUB,
STEERING KNUCKLE REMOVAL/
INSTALLATION.)
End Of Sie
2
aesffw00000450
03-11–1
FRONT AXLE
WHEEL HUB, STEERING KNUCKLE REMOVAL/INSTALLATION
id031100800400
Removal
Note
• Install a new wheel bearing when the wheel hub is removed.
1. Remove the front disc plate. (See 04-11-22 DISC PLATE REMOVAL/INSTALLATION.)
2. Remove the locknut.
atraaw00001494
3. Remove the tie-rod end nut.

(1) Remove the cotter pin.
(2) Remove the nut.
1 2
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4. Disconnect the tie-rod end from the knuckle using

the SST.
49 T028 3A0
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5. Remove the bolt and position the ABS sensor out

of the way.
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03-11–2
FRONT AXLE
6. Disconnect the lower ball joint form the steering
knuckle.
(1) Remove the pinch bolt.
(2) Disconnect the lower ball joint form the
steering knuckle.
7. Disconnect the drive shaft form the knuckle.
(1) Position the drive shaft out of the way and 1
support.
atraaw00001498
8. Remove the steering knuckle.

(1) Remove the strut-to-steering knuckle bolts.
(2) Remove the steering knuckle.
1
03
2
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9. Remove the wheel hub from the wheel bearing

knuckle using the SSTs. 49 G033 102
49 G033 105
49 W017 101
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10. Grind the bearing inner race until approx. 0.5 mm

remains using a grinder.
Caution
• Do not damage the wheel hub by using a
grinder or a chisel.
Note
• This step is not needed if the inner wheel
bearing race remains on the steering
knuckle after removing the wheel hub.
atraaw00001501
11. Break off and remove the bearing inner race
using a chisel.
03-11–3
FRONT AXLE
12. Remove the snap ring.
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13. Remove the bearing outer race from the steering

knuckle using the SSTs. 49 G030 797
49 F027 005
49 S033 101
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14. Remove the dust cover if necessary.
Note
• The dust cover is pressed on.
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Installation
1. Install the dust cover if necessary.
49 S033 101
49 F027 009
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03-11–4
FRONT AXLE
2. Install the wheel bearing to the wheel hub using
the SSTs.
49 F027 009
49 H026 104
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3. Install the snap ring.
03
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4. Press fit a wheel hub into the wheel bearing using

the SSTs.
49 G033 102
49 G033 105
49 F027 005
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5. Install the steering knuckle.

• Position the steering knuckle.
6. Install the drive shaft to the wheel hub.
atraaw00001509
7. Install the bolt to the steering knuckle.

• Position and align the ball joint stud into the
steering knuckle.
43.1—60.8 N·m
{4.40—6.19 kgf·m,
31.8—44.8 ft·lbf}
atraaw00001510
03-11–5
FRONT AXLE
8. Install the ABS sensor and tighten the bolt.
7.8—10.8 N·m
{80—110 kgf·cm,
69.1—95.5 in·lbf}
atraaw00001511
9. Install the outer ball joint to the steering knuckle.

• Install the outer ball joint nut.
• Install a new cotter pin.
2 48.8—63.6 N·m
1 {4.98—6.48 kgf·m,
36.0—46.9 ft·lbf}
atraaw00001512
10. Install a new wheel hub nut.

11. Install the brake disc. (See 04-11-22 DISC PLATE 270—310 N·m
{27.6—31.6 kgf·m,
REMOVAL/INSTALLATION.) 200—228 ft·lbf}
End Of Sie
WM: WHEEL HUB
atraaw00001513
WHEEL HUB BOLT REMOVAL/INSTALLATION

id031100800500
1. Remove the brake caliper component and disc plate.
2. Remove the wheel hub bolt using the SST as
Note
• If the dust cover interferes with the wheel
hub bolt and the wheel hub bolt cannot be
removed, tap the part shown in the figure
with a chisel and bend the processing point
BEND THIS PART
back to the steering knuckle side.
3. Place a new wheel hub bolt in the wheel hub. 49 T028 3A0
BUE0315W004
03-11–6
FRONT AXLE
4. Install the wheel hub bolt by placing a proper
sized washer on the hub and tightening the nut as HUB BOLT
End Of Sie
WHEEL WHEEL
NUT BRASS NUT
BAR WASHER
A6E0311W012
03
03-11–7
REAR AXLE
03-12 REAR AXLE

REAR AXLE RUBBER BUSHING (WHEEL KNUCKLE)
REMOVAL/INSTALLATION. . . . . . . . . . 03-12–2 REMOVAL/INSTALLATION . . . . . . . . . . 03-12–7
End of Toc
WM: REAR AXLE
03
03-12–1
REAR AXLE
REAR AXLE REMOVAL/INSTALLATION
id031200800600
Removal
Note
• When installing a new wheel knuckle, install a new wheel bearing.
1. Remove the locknut.
atraaw00001541
2. Position the ABS sensor out of the way.

(1) Remove the ABS sensor bolt and the bracket
bolts. 1
(2) Position the ABS sensor out of the way.
atraaw00001542
3. Disconnect the parking brake cable.

4. Support the wheel knuckle.
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5. Remove the lower shock absorber nut.
atraaw00001545
03-12–2
REAR AXLE
6. Remove the lower ball joint.
• Remove the nut.
Note
• Hold the ball joint stud to keep it from turning
while removing the nut.
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7. Remove the upper ball joint.

• Remove the nut.
Note
• Hold the ball joint stud to keep it from turning
while removing the nut.
03
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8. Remove the spring.

• Remove the support to the wheel knuckle.
Note
• Mark the position of the spring insulator and
the spring for installation.
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9. Remove the wheel knuckle cam bolt.

(1) Mark the position of the adjustment cam
notch. 2
(2) Remove the wheel knuckle cam bolt.
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10. Remove the wheel knuckle.

(1) Remove the wheel knuckle cam.
(2) Remove the wheel knuckle.
1
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03-12–3
REAR AXLE
11. Remove the wheel hub from the wheel knuckle
using the SSTs. 49 G030 727
49 G033 102
49 F026 103
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13. Remove the wheel bearing from the wheel

knuckle using the SSTs. 49 F027 005
49 F027 003
49 F026 103
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Installation
1. Install a new wheel bearing to the wheel knuckle
using the SSTs.
49 F027 007
49 H026 104
atraaw00001554
03-12–4
REAR AXLE
2. Install the snap ring to the wheel knuckle.
atraaw00001555
3. Install the wheel hub to the wheel knuckle using

the SSTs. 49 G033 102
49 G030 727
03
49 D034 201
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4. Position the wheel knuckle and install the wheel

knuckle cam.
• Position the drive shaft into the wheel hub.
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5. Temporarily tighten the wheel knuckle cam bolt.
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6. Support the wheel knuckle and install the spring.
atraaw00001559
03-12–5
REAR AXLE
7. Install the lower shock absorber nut.
97.7—132.3 N·m
{9.97—13.494 kgf·m,
72.06—97.57 ft·lbf}
atraaw00001560
8. Install the upper ball joint.

• Install the nut.
97.7—132.3 N·m
{9.97—13.494 kgf·m,
72.06—97.57 ft·lbf}
atraaw00001561
9. Install the lower ball joint.

• Install the nut.
97.7—132.3 N·m
{9.97—13.494 kgf·m,
72.06—97.57 ft·lbf}
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10. Tighten the wheel knuckle cam bolt.

(1) Align the wheel knuckle cam.
(2) Tighten the wheel knuckle cam bolt.
1 2
97.7—132.3 N·m
{9.97—13.494 kgf·m,
72.06—97.57 ft·lbf}
atraaw00001563
11. Install the parking brake cable to the brake

backing plate.
(2) Install the parking brake cable to the brake
backing plate.
atraaw00002925
03-12–6
REAR AXLE
12. Install the ABS sensor and the bracket bolts.
• Install the bolt.
7.6—10.4 N·m
{76—106 kgf·cm,
67.3—92.0 in·lbf}
atraaw00001564
13. Install the locknut.

• Install the bolt.
14. Bleed the brake system. (See 04-11-2 AIR
BLEEDING (BRAKE SYSTEM).)
15. Inspect and adjust the wheel alignment if
necessary. (See 02-11-5 REAR WHEEL
ALIGNMENT.) 03
End Of Sie
270—310 N·m
{27.6—31.6 kgf·m,
200—228 ft·lbf}
atraaw00001565
RUBBER BUSHING (WHEEL KNUCKLE) REMOVAL/INSTALLATION

id031200800700
1. Remove the wheel knuckle. (See 03-12-2 REAR AXLE REMOVAL/INSTALLATION.)
2. Remove the stop rubber.
3. Remove the rubber bushing from the wheel
knuckle using the SSTs.
POSITION THE
LARGER HOLE
SIDE UPWARD
aesffw00000451
03-12–7
REAR AXLE
4. Install a new rubber bushing to the wheel knuckle
using the SSTs.
Caution
• Install the rubber bushing so that the
hollow sections are positioned
horizontally. POSITION THE
SMALLER HOLE
SIDE UPWARD
aesffw00000452
HOLLOW SECTION
HORIZON
aesffw00000518
5. Install the stop rubber.

BRIDGE SECTION
Caution
• Install the stop rubber so that the bridge
section is positioned directly above.
6. Install the wheel knuckle to the vehicle.

HORIZON
End Of Sie
aesffw00000519
03-12–8
DRIVE SHAFT
03-13 DRIVE SHAFT

JOINT SHAFT INSPECTION. . . . . . . . . . 03-13–1 FRONT DRIVE SHAFT
JOINT SHAFT DISASSEMBLY/ASSEMBLY[L3] . . . . . . 03-13–9
REMOVAL/INSTALLATION[L3] . . . . . . 03-13–2 FRONT DRIVE SHAFT
JOINT SHAFT DISASSEMBLY/ASSEMBLY
REMOVAL/INSTALLATION [AJ (3.0L Duratec)] . . . . . . . . . . . . . . . . 03-13–14
[AJ (3.0L Duratec)] . . . . . . . . . . . . . . . . 03-13–4 REAR DRIVE SHAFT INSPECTION . . . . 03-13–20
JOINT SHAFT REAR DRIVE SHAFT
DISASSEMBLY/ASSEMBLY[L3] . . . . . 03-13–5 REMOVAL/INSTALLATION . . . . . . . . . . 03-13–20
FRONT DRIVE SHAFT REAR DRIVE SHAFT
INSPECTION . . . . . . . . . . . . . . . . . . . . . 03-13–7 DISASSEMBLY/ASSEMBLY . . . . . . . . . 03-13–21
FRONT DRIVE SHAFT
End of Toc
JOINT SHAFT INSPECTION
WM: JOINT SHAFT
id031300801500
1. Inspect the connections for any looseness. 03
• If there is any malfunction, tighten or replace the applicable part.
2. Move the joint and bearing up and down, left and
right by hand and verify that there is no excessive
play.
• If there is any malfunction, replace the
applicable part.
End Of Sie
BMJ0313W587
03-13–1
DRIVE SHAFT
JOINT SHAFT REMOVAL/INSTALLATION[L3]
id0313008009a1
Caution
• Performing the following procedures without first removing the ABS wheel-speed sensor may
possibly cause an open circuit in the wiring harness if it is pulled by mistake. Before performing
the following procedures, disconnect the ABS wheel-speed sensor (axle side) and secure it to an
appropriate place where the sensor wiring harness will not be pulled by mistake while servicing
the vehicle.
1. Drain the ATF.

4. Add the ATF. (See 05-17A-9 AUTOMATIC TRANSAXLE FLUID (ATF) REPLACEMENT[GF4AX-EL]) (See 05-
17B-6 AUTOMATIC TRANSAXLE FLUID (ATF) REPLACEMENT[LA4AX-EL (CD4E)])
33.0—44.1
3.37—4.49 1 SST 42—62
24.4—32.5
{4.3—6.3,
31—45}
4 SST
R
5 R
43.1—58.8
{4.40—5.99,
31.8—43.3}
3
2
atraaw00002563
1 Tie-rod end 4 Joint shaft

(See 03-13-2 Tie-rod End Removal Note.) (See 03-13-3 Joint Shaft Removal Note.)
2 Lower arm ball joint (See 03-13-4 Joint Shaft Installation Note.)
(See 03-13-3 Lower Arm Ball Joint Removal Note.) 5 Clip
3 Drive shaft, axle component (See 03-13-4 Clip Installation Note.)
(See 03-13-3 Drive Shaft, Axle Component
Removal Note.)
Tie-rod End Removal Note

1. Detach the tie-rod end from the steering knuckle
using the SST.
49 T028 3A0
atraaw00002926
03-13–2
DRIVE SHAFT
Lower Arm Ball Joint Removal Note
1. Remove the lower arm ball joint bolt and nut.
2. Using a clean rag-wrapped tire lever or
equivalent, push down on the lower arm to
disconnect it from the steering knuckle.
Note
• Be careful not to damage the ball joint dust
boot.
RAG
atraaw00002565
Drive Shaft, Axle Component Removal Note

1. Using a brass bar and hammer, disconnect the
drive shaft from the joint shaft by tapping the
outer ring on the differential side. 03
Note
• Be careful not to damage the outer ring on
the differential side.
atraaw00002566
Joint Shaft Removal Note

1. Disconnect the joint shaft bracket from the
cylinder block and remove the joint shaft.
Caution
• The sharp edges of the joint shaft can
damage the oil seal. Be careful not to
damage the oil seal when removing the
joint shaft.
atraaw00002567
2. For the vehicle with GF4AX-EL, install the SST to

the transaxle after the joint shaft is removed. 49 G030 455
(GF4AX-EL)
atraaw00002568
03-13–3
DRIVE SHAFT
Clip Installation Note
1. Install a new joint shaft clip to the clip groove at
the end of the joint shaft.
CLIP
Clip width standard
31.2 mm {1.23 in} max.
OPENING
Note
• Install the clip with the clip width within the
specification. OUTER
DIAMETER
• Install the clip with the clip opening facing
upward.
atraaw00002569
Joint Shaft Installation Note

1. Install the joint shaft to the transaxle.
Caution
• The sharp edges of the joint shaft can damage the oil seal. Be careful not to damage the oil seal
when removing the joint shaft.
End Of Sie
JOINT SHAFT REMOVAL/INSTALLATION[AJ (3.0L Duratec)]
id0313008009a2
1. Remove the drive shaft (RH). (See 03-13-7 FRONT DRIVE SHAFT REMOVAL/INSTALLATION.)
2. Remove the two inner linkshaft bearing retainer
nuts.
22—30 N·m
{2.3—3.0 kgf·m,
17—22 ft·lbf}
atraaw00002624
3. Remove the inner linkshaft.

End Of Sie
atraaw00002625
03-13–4
DRIVE SHAFT
JOINT SHAFT DISASSEMBLY/ASSEMBLY[L3]
id0313008014a1
R
SST R
GREASE
5 SST
4
3
6 7
R 1 7.8—10.8 N·m
{80—110 kgf·cm,
SST 69.1—95.5 in·lbf}
GREASE
03
7.8—10.8 N·m
1
{80—110 kgf·cm,
69.1—95.5 in·lbf}
2 SST
atraaw00002617
1 Bolt 5 Bearing
2 Joint shaft (See 03-13-6 Dust Seal (Differential Side), Bearing
(See 03-13-5 Joint Shaft Disassembly Note.) Disassembly Note.)
(See 03-13-7 Joint Shaft Assembly Note.) (See 03-13-6 Bearing Assembly Note.)
3 Dust cover 6 Dust seal (drive shaft side)
(See 03-13-6 Dust Seal (Drive Shaft Side) Assembly
4 Dust seal (differential side) Note.)
(See 03-13-6 Dust Seal (Differential Side) Assembly
Note.) 7 Bracket
Joint Shaft Disassembly Note

1. Loosen the dust cover installation bolt and remove the dust cover from the bracket.
2. Remove the joint shaft using a press.
BAR
atraaw00002618
03-13–5
DRIVE SHAFT
Dust Seal (Differential Side), Bearing Disassembly Note
1. Remove the dust seal (differential side) and the
bearing using the SSTs and a press.
49 B014 001
49 H034 201
atraaw00002619
Dust Seal (Drive Shaft Side) Assembly Note

1. Apply grease to a new dust seal lip, and press fit
the seal using the SSTs.
49 F027 003
49 B025 004
atraaw00002620
Bearing Assembly Note

1. Press fit a new bearing using the SSTs.
49 F027 005 49 F027 003
49 S231 626
atraaw00002621
Dust Seal (Differential Side) Assembly Note

1. Apply grease to a new dust seal lip, and press fit
the seal using the SSTs.
STEEL PLATE
atraaw00002622
03-13–6
DRIVE SHAFT
Joint Shaft Assembly Note
1. Press fit the joint shaft using the SSTs.
End Of Sie
WM: FRONT DRIVE SHAFT
49 F401 336B
atraaw00002623
FRONT DRIVE SHAFT INSPECTION

id031300801200
1. Inspect the connections for any looseness.
2. Inspect the dust boot for damage and cracks.
3. Move the spline and joint up and down, left and
03
right by hand and verify that there is no excessive
play.
• If there is any malfunction, replace the
applicable part.
End Of Sie
WM: DRIVE SHAFT
aesffw00000456
FRONT DRIVE SHAFT REMOVAL/INSTALLATION

id031300800300
Removal
Note
• The figure shows RH, The procedure for LH is the same.
1. Remove the front brake disk. (See 04-11-22 DISC PLATE REMOVAL/INSTALLATION.)
2. Remove and discard the front axle wheel hub nut.
3. Remove the brake hose clip.
atraaw00001575
03-13–7
DRIVE SHAFT
4. Remove the tie-rod end nut.
(1) Remove the cotter pin.
(2) Remove the tie-rod end.
1 2
atraaw00001576
5. Disconnect the tie-rod end from the steering

knuckle using the SST.
6. Disconnect the upper side of the stabilizer control
link.
49 T028 3A0
atraaw00001577
7. Disconnect the lower ball joint from the steering

knuckle.
(1) Remove the pinch bolt and nut.
(2) Disconnect the lower ball joint from the
steering knuckle.
8. Remove the front drive shaft.
1
atraaw00001578
Installation
1. Position the front drive shaft and joint so that the splines line up with the differential side gear splines. Install the
front drive shaft and the joint to the differential side gear.
Note
• When installed correctly, the drive shaft bearing retainer clip fits to the differential side gear groove.
2. Position the drive shaft to the steering knuckle.

3. Install the lower ball joint pinch bolt and nut.
4. Install the tie-rod end.
Note
• If the nut groove and the ball joint hole are
not aligned, tighten the nut as necessary.
(1) Position the tie-rod end.

(2) Install the tie-rod end nut and cotter pin.
43.1—60.8 N·m
{4.40—6.19 kgf·m,
31.8—44.8 ft·lbf}
atraaw00001579
03-13–8
DRIVE SHAFT
5. Install a new front axle wheel hub nut. 270—310 N·m
End Of Sie {27.6—31.6 kgf·m,
200—228 ft·lbf}
atraaw00001580
FRONT DRIVE SHAFT DISASSEMBLY/ASSEMBLY[L3]

id0313008004a1
1. Disassemble in the order indicated in the table.
SST 1
R 03
GREASE
GREASE
1 SST
R 2
R
8
RH
5
R
GREASE
6
2
7 R
R 4
3
atraaw00002606
1 Boot band (wheel side) 4 Snap ring

(See 03-13-10 Boot Band (Wheel Side) (See 03-13-10 Snap Ring, Tripod Joint Disassembly
Disassembly Note.) Note.)
(See 03-13-13 Boot Band (Wheel Side) Assembly (See 03-13-12 Tripod Joint, Snap Ring Assembly
Note.) Note.)
2 Boot band (differential side) 5 Tripod joint
(See 03-13-10 Boot Band (Differential Side) (See 03-13-10 Snap Ring, Tripod Joint Disassembly
Disassembly Note.) Note.)
(See 03-13-12 Boot Band (Differential Side) (See 03-13-12 Tripod Joint, Snap Ring Assembly
Assembly Note.) Note.)
3 Outer ring 6 Boot
(See 03-13-10 Outer Ring Disassembly Note.) (See 03-13-11 Boot Disassembly Note.)
(See 03-13-12 Outer Ring Assembly Note.) (See 03-13-11 Boot Assembly Note.)
7 Dynamic damper
(See 03-13-11 Dynamic Damper Assembly Note.)
8 Shaft, bell joint component
03-13–9
DRIVE SHAFT
Boot Band (Wheel Side) Disassembly Note
Note
• Remove the boot band only if there is a malfunction.
1. Remove the boot band using end clamp pliers.
atraaw00002607
Boot Band (Differential Side) Disassembly Note

1. Press the lock clip upward using a flathead screwdriver.
2. Remove the boot band using pliers.
atraaw00002608
Outer Ring Disassembly Note

1. Place an alignment mark on the outer ring (tripod
side) and the drive shaft.
2. Remove the outer ring.
MARK
atraaw00002609
Snap Ring, Tripod Joint Disassembly Note

1. Place an alignment mark on the shaft and tripod
joint.
2. Remove the snap ring from the shaft using snap
ring pliers.
3. Remove the tripod joint.
Caution
• Do not tap the tripod joint with a hammer.
MARK
atraaw00002610
03-13–10
DRIVE SHAFT
Boot Disassembly Note
Note
• Remove the wheel side boot only if there is any malfunction.
1. Wrap the shaft splines with tape and remove the

boot.
TAPE
atraaw00002611
Dynamic Damper Assembly Note 03

1. Install the dynamic damper with the length shown
in the figure within the specification. DYNAMIC DAMPER
Standard
291.0—297.4 mm {11.46—11.70 in}
atraaw00002612
Boot Assembly Note

1. Fill the inside of the new dust boot (wheel side) with grease.
Warning
• Do not touch the grease with your hand. Apply it from the tube to prevent foreign matter from
entering the boot.
Note
• The boot shapes on the wheel side and the differential side are different. Do not install the wrong boot by
mistake.
• Apply the repair kit grease
Grease amount
105—125 g {3.7—4.4 oz}
2. Assemble the boot with the shaft spline wrapped with tape.
3. Remove the tape.
03-13–11
DRIVE SHAFT
Tripod Joint, Snap Ring Assembly Note
1. While aligning the marks on the shaft and the
tripod joint, insert the tripod joint.
MARK
Caution
• Do not tap the roller with a hammer.
2. Insert a new snap ring using snap ring pliers.
Caution
• Be sure the snap ring engages correctly
in the groove of the shaft.
atraaw00002613
Outer Ring Assembly Note

1. Apply the outer ring and boot (differential side) with the repair kit grease.
Warning
• Do not touch the grease with your hand. Apply it from the tube to prevent foreign matter from
entering the boot.
Grease amount
200—220 g {7.1—7.7 oz}
2. Assemble the outer ring.

3. Set the drive shaft to the standard length.
Standard
Left side: 648.2—658.2 mm {25.52—25.91 in}
Right side: 601.2—611.2 mm {23.67—24.06 in}
4. Release any trapped air from the boots by

carefully lifting up the small end of each boot with
a clean rag-wrapped flathead screwdriver.
Caution
• Do not let the grease leak.
• Do not damage the boot.
5. Verify that the drive shaft length is within the

specification under atmospheric pressure inside
the boot.
• If not within the specification, readjust.
atraaw00002614
Boot Band (Differential Side) Assembly Note

1. Set a new boot band to the boot slot.
Caution
• Remove grease from the boot slot.
• Bend the boot band to the opposite
direction of drive shaft forward rotation
direction.
2. After pulling the tip of the boot band with pliers,

crimp it.
3. Fold back the clip to secure the boot band.
atraaw00002615
Caution
• Verify that the boot band is installed
securely to the boot slot.
03-13–12
DRIVE SHAFT
Boot Band (Wheel Side) Assembly Note
1. Adjust clearance A by turning the adjusting bolt of
the SST.
Clearance A ADJUSTING BOLT

2.9 mm {0.11 in}
A
2. Crimp the wheel side small boot band using the

SST. Verify that clearance B is within the
specification.
• If clearance B is more than the specification,
reduce clearance A of the SST and crimp the
boot again.
• If clearance B is less than the specification,
atraaw00002616
replace the boot band, increase clearance A

of the SST, and crimp the new boot.
Clearance B
2.4—2.8 mm {0.095—0.110 in}
03
3. Verify that the boot band does not protrude from the boot band installation area.
• If it does, replace the boot band and repeat
steps 2 and 3. B
4. Fill the boot with the repair kit grease.
5. Adjust clearance A by turning the adjusting bolt of
the SST.
Clearance A 49 T025 001

3.2 mm {0.13 in}
6. Crimp the wheel side big boot band using the

SST.
7. Verify that clearance B is within the specification.
• If clearance B is more than the specification,
acxuuw00001252
reduce clearance A of the SST and crimp the

boot again.
• If clearance B is less than the specification, replace the boot band, increase clearance A of the SST and
crimp the new boot.
Clearance B
2.4—2.8 mm {0.095—0.110 in}
8. Verify that the boot band does not protrude from the boot band installation area.
• If it does, replace the boot band and repeat steps 7 and 8.
End Of Sie
03-13–13
DRIVE SHAFT
FRONT DRIVE SHAFT DISASSEMBLY/ASSEMBLY[AJ (3.0L Duratec)]
id0313008004a2
Disassembly
1. Remove the drive shaft. (See 03-13-7 FRONT DRIVE SHAFT REMOVAL/INSTALLATION.)
2. Secure the drive shaft in a vice using protective
jaw covers.
atraaw00002661
3. Remove the boot band.
atraaw00002662
4. Slide and remove the boot.
atraaw00002663
5. Disconnect the tripod joint from the outer ring.
atraaw00002664
03-13–14
DRIVE SHAFT
6. If reinstalling the tripod joint, mark the tripod joint
and the drive shaft for correct installation.
atraaw00002665
03
atraaw00002666
8. Remove the tripod joint.
atraaw00002667
9. Remove the boot from the drive shaft.
atraaw00002668
10. Remove the two boot bands (wheel side).
atraaw00002669
03-13–15
DRIVE SHAFT
11. Slide the boot back out of the way to expose the
joint (wheel side).
atraaw00002670
12. Remove and dispose the retainer clip.
atraaw00002671
13. Slide and remove the boot (wheel side) from the
drive shaft.
atraaw00002672
Assembly
1. Lubricate the joint (wheel side) with the BALL JOINT ADDITIVE.
Note
• Verify that all components are clean and free of foreign material.
atraaw00002673
03-13–16
DRIVE SHAFT
2. Install the boot.
atraaw00002674
3. Install a new retainer clip.
03
atraaw00002675
4. Remove any excess grease on the mating

surfaces and slide the boot forward onto the joint.
atraaw00002676
5. Remove any excess air trapped in the boot using

a cloth covered screwdriver after installing the
boot correctly.
6. Assemble a new boot band.
acxuuw00001249
(1) Adjust clearance A by turning the adjusting

bolt of the SST.

2.9 mm {0.11 in}
A
atraaw00002677
03-13–17
DRIVE SHAFT
(2) Crimp the wheel side small boot band using the SST. Verify that clearance B is within the specification.
• If clearance B is more than the specification, reduce clearance A of the SST and crimp the boot again.
• If clearance B is less than the specification, replace the boot band, increase clearance A of the SST,
and crimp the new boot.
Clearance B
2.4—2.8 mm {0.095—0.110 in}
(3) Verify that the boot band does not protrude from the boot band installation area.
• If it does, replace the boot band and
repeat steps 2 and 3. B
(4) Fill the boot with the repair kit grease.
bolt of the SST.
Clearance A 49 T025 001

3.2 mm {0.13 in}
(6) Crimp the wheel side big boot band using the
SST.
(7) Verify that clearance B is within the
acxuuw00001252
specification.
• If clearance B is more than the
specification, reduce clearance A of the SST and crimp the boot again.
• If clearance B is less than the specification, replace the boot band, increase clearance A of the SST
Clearance B
2.4—2.8 mm {0.095—0.110 in}
• If it does, replace the boot band and repeat steps (7) and (8).
7. Fill the boot with the repair kit grease.
8. Position the boot (differential side).
atraaw00002678
9. Install the tripod joint to the drive shaft.

(1) Align the marks on the drive shaft and tripod
joint.
(2) Install the tripod joint to the drive shaft.
atraaw00002679
03-13–18
DRIVE SHAFT
atraaw00002680
11. Lubricate the three tripod joint needle bearings.
03
atraaw00002681
12. Lubricate inside the tripod joint with the BALL

JOINT ADDITIVE.
atraaw00002682
13. Position the outer ring onto the tripod.
atraaw00002664

(1) Position the boot.
(2) Position the boot band.
atraaw00002683
03-13–19
DRIVE SHAFT
boot correctly.
16. Follow the same procedures to install the two new
boot bands on the opposite side.
17. Install the drive shaft. (See 03-13-7 FRONT
DRIVE SHAFT REMOVAL/INSTALLATION.)
End Of Sie
WM: REAR DRIVE SHAFT
acxuuw00001249
REAR DRIVE SHAFT INSPECTION

id031300801300
1. Inspect the connections for any looseness.
2. Inspect the dust boot for damage and cracks.
3. Move the spline and joint up and down, left and right by hand and verify that there is no excessive play.
End Of Sie
REAR DRIVE SHAFT REMOVAL/INSTALLATION
id031300800600
1. Disconnect the ABS wheel-speed sensor wiring harness connector (axle side) and secure the wiring harness
to an appropriate place where it will not be pulled by mistake while servicing the vehicle.
2. Remove the rear coil spring. (See 02-14-2 REAR COIL SPRING REMOVAL/ INSTALLATION.)
3. Remove the nuts and disconnect the upper and
lower ball joints.
Caution
• Support the wheel knuckle securely.
97.7—132.3 N·m
{9.97—13.49 kgf·m,
72.06—97.57 ft·lbf}
atraaw00002545
4. Remove the bolt and disconnect the rear knuckle

from the vehicle. 97.7—132.3 N·m
{9.97—13.49 kgf·m,
Note 72.06—97.57 ft·lbf}
• Mark the position of the knuckle bolt and
cam assembly for correct installation.
atraaw00002546
03-13–20
DRIVE SHAFT
5. Remove and discard the nut.
6. Disconnect the parking brake cable.
7. Disconnect the brake pipes.
8. Loosen the shock absorber lower bolt (member
side).
9. Loosen the upper arm rod bolt (member side).
10. Loosen the lower arm rod bolt (member side).
11. Disconnect the upper arm (knuckle side).
12. Disconnect the lower arm (knuckle side).
270—310 N·m
13. Disconnect the rear drive shaft from the knuckle. {27.6—31.6 kgf·m,
14. Install in the reverse order of removal. 200—228 ft·lbf}
REAR DRIVE SHAFT DISASSEMBLY/ASSEMBLY

id031300800700
Disassembly
1. Remove the rear drive shaft. (See 03-13-20 REAR DRIVE SHAFT REMOVAL/INSTALLATION.)
2. Secure the drive shaft in a vice using protective
jaw covers.
03
aesffw00000461
3. Remove the boot band (differential side).
aesffw00000462
4. Slide and remove the boot.
aesffw00000463
03-13–21
DRIVE SHAFT
5. If reinstalling the inner joint, mark the inner joint
and the drive shaft for correct installation.
aesffw00000464
6. Disconnect the drive shaft using a plastic

hammer.
aesffw00000465
7. Remove and discard the retainer clip.
aesffw00000466
8. Remove and discard the snap ring.
aesffw00000467
9. Remove the boot from the drive shaft.
aesffw00000468
03-13–22
DRIVE SHAFT
10. Remove the two boot bands (wheel side).
aesffw00000469
11. Slide the boot back out of the way to expose the
joint.
03
aesffw00000470
12. Remove and discard the retainer clip.
aesffw00000466
13. Remove the snap ring from the drive shaft.
aesffw00000467
14. Slide the remove the boot from the drive shaft.
aesffw00000471
03-13–23
DRIVE SHAFT
Assembly
1. Lubricate the joint with grease.
aesffw00000472
2. Install the boot (wheel side).
aesffw00000473
3. Install the snap ring to the drive shaft.
aesffw00000467
4. Install a new retainer clip.
aesffw00000466
03-13–24
DRIVE SHAFT
5. Use a plastic hammer to install the joint
(differential side) by gently tapping it onto the
drive shaft.
aesffw00000474
6. Remove any excess grease on the mating

surfaces and slide the boot (wheel side) forward
onto the joint.
03
aesffw00000475

boot correctly.
8. Assemble a new boot band.
aesffw00000476

bolt of the SST.

2.9 mm {0.11 in}
A
(2) Crimp the wheel side small boot band using

the SST. Verify that clearance B is within the
specification.
• If clearance B is more than the
specification, reduce clearance A of the
SST and crimp the boot again.
• If clearance B is less than the
aesffw00000477
specification, replace the boot band,

increase clearance A of the SST, and crimp the new boot.
Clearance B
2.4—2.8 mm {0.095—0.110 in}
03-13–25
DRIVE SHAFT
(3) Verify that the boot band does not protrude
from the boot band installation area. B
• If it does, replace the boot band and
repeat steps 2 and 3.
(4) Fill the boot with the repair kit grease.
bolt of the SST. 49 T025 001
Clearance A
3.2 mm {0.13 in}
(6) Crimp the wheel side big boot band using the
acxuuw00001252
SST.
(7) Verify that clearance B is within the
specification.
• If clearance B is more than the specification, reduce clearance A of the SST and crimp the boot again.
• If clearance B is less than the specification, replace the boot band, increase clearance A of the SST
Clearance B
2.4—2.8 mm {0.095—0.110 in}
• If it does, replace the boot band and repeat steps (7) and (8).
aesffw00000478
aesffw00000467
11. Install the retainer clip.
aesffw00000466
03-13–26
DRIVE SHAFT
12. Position the boot (wheel side).
aesffw00000479

boot correctly.
14. Follow the same procedures to install the two new
boot bands on the opposite side.
15. Install the rear drive shaft. (See 03-13-20 REAR
DRIVE SHAFT REMOVAL/INSTALLATION.) 03
End Of Sie
aesffw00000476
03-13–27

Ford Escape F1A3!10!06C - 2

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Ford Escape F1A3!10!06C - 2

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MECHANICAL [L3]

1 No.2 engine mount through bolt 5 No.3 engine mount bracket

Engine Mount Member, No.2 Engine Mount Rubber Removal Note

FRONT FOOT No.1

FRONT FOOT No.2

(1) Install the right rear shaft of the SST to the

2. Support the engine using the SST.

3. Remove the engine mount member and No.2

No.3 Engine Mount Bracket Removal Note

2. Remove the SST.

4. Tighten the new No.4 engine mount bracket bolts,

No.3 Engine Mount Bracket Installation Note

2. Install the No.3 engine mount bracket and

3. Tighten the No.3 engine mount bracket bolt and

FRONT FOOT No.1

FRONT FOOT No.2

(1) Install the right rear shaft of the SST to the

(3) Install the left/right front shaft of the SST with

6. Remove the engine jack.

No.1 Engine Mount Rubber Installation Note

Engine Mount Member, No.2 Engine Mount Rubber Installation Note

1. Tighten the engine mount member bolts and nut.

2. Remove the SST.

4. Tighten the No.2 engine mount through bolt.

1. Disconnect the negative battery cable.

VARIABLE VALVE TIMING ACTUATOR REMOVAL/INSTALLATION[L3]

OIL CONTROL VALVE (OCV) INSPECTION[L3]

Oil control valve resistance

4. Connect the oil control valve connector.

6. Stop applying battery positive voltage and verify

Idle Speed Inspection

Idle speed (N position)

Idle Mixture Inspection

01-10B MECHANICAL [AJ (3.0L Duratec)]

1 Front drive belt 3 Engine

1. Verify that the drive belt auto tensioner indicator

Water Pump Drive Belt

3. Turn the drive belt auto tensioner clockwise to AUTO

Water Pump Drive Belt Removal/Installation

4. Hold down the belt while cutting as shown in the

1. Secure the water pump drive pulley and the belt

3. Verify that the belt is installed securely in the pulley groove.

4. Remove the tie wrap.

5. Install the bolts, nut and front lower splash shield.

COMPRESSION INSPECTION[AJ (3.0L Duratec)]

(3) Repeat the test on each cylinder, cranking the

7. Install the fuel pump relay.

20—30 {2.1—3.0, 15—22}

20—30 {2.1—3.0, 15—22}

8—12 N·m 2 SEALANT

20—30 {2.1—3.0, 15—22} 5

1 Drive belt auto tensioner 5 Engine front cover

Engine Front Cover Installation Note

1. Apply a 6 mm {0.24 in} diameter dot of Silicone

CYLINDER HEAD COVER (LH) REMOVAL/INSTALLATION[AJ (3.0L Duratec)]

4. Disconnect the wiring harness from the cylinder

6. Remove the cylinder head cover bolts and studs 11

3. Position the cylinder head cover and install the

5. Connect the wiring harness to the cylinder head

6. Install the ignition coils (LH).

CYLINDER HEAD COVER (RH) REMOVAL/INSTALLATION[AJ (3.0L Duratec)]

4. Disconnect the condenser.