Oreion Motors TECHNICAL MANUAL Small Size Final

Oreion
Motors
Vehicle
TECHNICAL MANUAL
Introduction
Foreword
This manual is written for an experienced technician. Information is organized in groups for the various
Essential tools required in performing certain service work components requiring service instruction. At the
are identified in this manual and are recommended for use. beginning of each group are summary listings of all
Live with safety: Read the safety messages in the applicable essential tools, service equipment and tools,
introduction of this manual and the cautions presented other materials needed to do the job, service parts kits,
throughout the text of the manual. specifications, wear tolerances, and torque values.
Technical Manuals are concise guides for specific
This is the safety-alert symbol. When you see this machines. They are on-the-job guides containing only the
symbol on the machine or in this manual, be alert to the vital information needed for diagnosis, analysis, testing,
potential for personal injury. and repair.
Technical manuals are divided in two parts: repair and Fundamental service information is available from other
operation and tests. Repair sections tell how to repair sources covering basic theory of operation, fundamentals
the components. Operation and tests sections help you of troubleshooting, general maintenance, and basic type
identify the majority of routine failures quickly. of failures and their causes.
Contents
Section 10—Safety Group 15—Theory of Operation
Group 05—Safety Group 20—Diagnosis
Group 25—Tests and Adjustments
Section 20—Specifications Group 30—Repair
Group 05—Specifications
Group 10—O-Ring Seal Service Recommendations Section 80—Miscellaneous
Group 15—General Information Group 05—Specifications
Group 20—Coolant Group 10—Component Location
Group 25—Serial Number Locations Group 15—Repair
Section 30—Engine – Gas Section 299—Service Tools

Group 05—Specifications Group 10—Service Tools and Kits
Group 10—Component Location
Group 15—Diagnostics
Group 25—Repair
Section 40—Electrical
Group 05—General Information
Group 20—Schematics and Harnesses (SN -060000)
Group 22—Schematics and Harnesses (SN 060001-)
Group 25—Operation and Diagnostics (SN -060000)
Group 30—Operation and Diagnostics - Fuel Injection
Group 35—Operation and Diagnostics - DTCs
Group 40—Operation and Diagnostics (SN 060001-)
Group 45—Operation and Diagnostics - Electronic
Controllers (SN 060001-)
Section 50—Power Train

Group 15—Theory of Operation
Group 20—Diagnostics
Group 30—Repair
Section 60—Steering
Group 15—Theory of Operation
Group 20—Diagnosis
Group 30—Repair
Section 70—Brakes
Original Instructions. All information, illustrations and specifications in this

manual are based on the latest information available at the time of publication.
The right is reserved to make changes at any time without notice.
COPYRIGHT © 2014
Oreion Motors
i
Section 10
Safety
Contents
Page
Group 05—Safety
Recognize Safety Information ....................... 10-05-1
Understand Signal Words.............................. 10-05-1
Replace Safety Signs .................................... 10-05-1
Handle Fluids Safely—Avoid
Fires........................................................... 10-05-2
Prepare for Emergencies............................... 10-05-2
Prevent Battery Explosions ........................... 10-05-2
Prevent Acid Burns........................................ 10-05-3
Wear Protective Clothing............................... 10-05-3
Avoid High-Pressure Fluids ........................... 10-05-4
Avoid Heating Near Pressurized
Fluid Lines ................................................. 10-05-4
Service Machines Safely ............................... 10-05-4
Use Proper Tools ........................................... 10-05-5
Park Machine Safely...................................... 10-05-5
Support Machine Properly ............................. 10-05-5
Use Proper Lifting Equipment........................ 10-05-6
Work in Clean Area ....................................... 10-05-6
Protect Against High Pressure
Spray ......................................................... 10-05-6
Illuminate Work Area Safely .......................... 10-05-7
Work In Ventilated Area................................. 10-05-7
Remove Paint Before Welding or
Heating ...................................................... 10-05-7
Avoid Harmful Asbestos Dust........................ 10-05-8
Service Tires Safely....................................... 10-05-8
Stay Clear of Rotating Drivelines................... 10-05-9
Service Cooling System Safely ..................... 10-05-9
Dispose of Waste Properly .......................... 10-05-10
Handle Chemical Products Safely................ 10-05-10
Live With Safety........................................... 10-05-10
10-1
Group 05
Safety
Recognize Safety Information
This is a safety-alert symbol. When you see this symbol
on your machine or in this manual, be alert to the potential
for personal injury.
Follow recommended precautions and safe operating
practices.
Understand Signal Words

A signal word—DANGER, WARNING, or CAUTION—is
used with the safety-alert symbol. DANGER identifies the
most serious hazards.
DANGER or WARNING safety signs are located near
specific hazards. General precautions are listed on
CAUTION safety signs. CAUTION also calls attention to
safety messages in this manual.
Replace Safety Signs

Replace missing or damaged safety signs. See the
machine operator’s manual for correct safety sign
placement.
10-05-1
Safety
Handle Fluids Safely—Avoid Fires

When you work around fuel, do not smoke or work near
heaters or other fire hazards.
Store flammable fluids away from fire hazards. Do not
incinerate or puncture pressurized containers.
Make sure machine is clean of trash, grease, and debris.
Do not store oily rags; they can ignite and burn
spontaneously.
Prepare for Emergencies

Be prepared if a fire starts.
Keep a first aid kit and fire extinguisher handy.
Keep emergency numbers for doctors, ambulance service,
hospital, and fire department near your telephone.
Prevent Battery Explosions

Keep sparks, lighted matches, and open flame away from
the top of battery. Battery gas can explode.
Never check battery charge by placing a metal object
across the posts. Use a volt-meter or hydrometer.
Do not charge a frozen battery; it may explode. Warm
battery to 16°C (60°F).
10-05-2
Safety
Prevent Acid Burns

Sulfuric acid in battery electrolyte is poisonous. It is strong
enough to burn skin, eat holes in clothing, and cause
blindness if splashed into eyes.
Avoid the hazard by:
1. Filling batteries in a well-ventilated area.
2. Wearing eye protection and rubber gloves.
3. Avoiding breathing fumes when electrolyte is added.
4. Avoiding spilling or dripping electrolyte.
5. Use proper jump start procedure.
If you spill acid on yourself:
1. Flush your skin with water.
2. Apply baking soda or lime to help neutralize the acid.
3. Flush your eyes with water for 15—30 minutes. Get
medical attention immediately.
If acid is swallowed:
1. Do not induce vomiting.
2. Drink large amounts of water or milk, but do not
exceed 2 L (2 quarts).
3. Get medical attention immediately.
Wear Protective Clothing

Wear close fitting clothing and safety equipment
appropriate to the job.
Prolonged exposure to loud noise can cause impairment
or loss of hearing.
Wear a suitable hearing protective device such as
earmuffs or earplugs to protect against objectionable or
uncomfortable loud noises.
Operating equipment safely requires the full attention of
the operator. Do not wear radio or music headphones
while operating machine.
10-05-3 053013
Safety
Avoid High-Pressure Fluids

Inspect hydraulic hoses periodically – at least once
per year – for leakage, kinking, cuts, cracks, abrasion,
blisters, corrosion, exposed wire braid or any other signs
of wear or damage.
Replace worn or damaged hose assemblies immediately
with Oreion Motors approved replacement parts.
Escaping fluid under pressure can penetrate the skin
causing serious injury.
Avoid the hazard by relieving pressure before
disconnecting hydraulic or other lines. Tighten all
connections before applying pressure.
with this type of injury should reference a knowledgeable
Search for leaks with a piece of cardboard. Protect hands medical source.
and body from high-pressure fluids.
If an accident occurs, see a doctor immediately. Any fluid
injected into the skin must be surgically removed within
a few hours or gangrene may result. Doctors unfamiliar
Avoid Heating Near Pressurized Fluid Lines

Flammable spray can be generated by heating near
pressurized fluid lines, resulting in severe burns to yourself
and bystanders. Do not heat by welding, soldering,
or using a torch near pressurized fluid lines or other
flammable materials. Pressurized lines can accidentally
burst when heat goes beyond the immediate flame area.
Service Machines Safely

Tie long hair behind your head. Do not wear a necktie,
scarf, loose clothing, or necklace when you work near
machine tools or moving parts. If these items were to get
caught, severe injury could result.
Remove rings and other jewelry to prevent electrical
shorts and entanglement in moving parts.
10-05-4 053013
Safety
Use Proper Tools

Use tools appropriate to the work. Makeshift tools and
procedures can create safety hazards.
Use power tools only to loosen threaded parts and
fasteners.
For loosening and tightening hardware, use the correct
size tools. DO NOT use U.S. measurement tools on
metric fasteners. Avoid bodily injury caused by slipping
wrenches.
Use only service parts meeting Oreion Motors specifications.
Park Machine Safely

Before working on the machine:
• Lower all equipment to the ground.
• Stop the engine and remove the key.
• Disconnect the battery ground strap.
• Hang a "DO NOT OPERATE" tag in operator station.
Support Machine Properly

Always lower the attachment or implement to the ground
before you work on the machine. If the work requires
that the machine or attachment be lifted, provide secure
support for them. If left in a raised position, hydraulically
supported devices can settle or leak down.
Do not support the machine on cinder blocks, hollow tiles,
or props that may crumble under continuous load. Do not
work under a machine that is supported solely by a jack.
Follow recommended procedures in this manual.
When implements or attachments are used with a
machine, always follow safety precautions listed in the
implement or attachment operator's manual.
10-05-5
Safety
Use Proper Lifting Equipment

Lifting heavy components incorrectly can cause severe
injury or machine damage.
Follow recommended procedure for removal and
installation of components in the manual.
Work in Clean Area

Before starting a job:
• Clean work area and machine.
• Make sure you have all necessary tools to do your job.
• Have the right parts on hand.
• Read all instructions thoroughly; do not attempt
shortcuts.
Protect Against High Pressure Spray

Spray from high pressure nozzles can penetrate the skin
and cause serious injury. Keep spray from contacting
hands or body.
If an accident occurs, see a doctor immediately. Any high
pressure spray injected into the skin must be surgically
removed within a few hours or gangrene may result.
Doctors unfamiliar with this type of injury should reference
a knowledgeable medical source.
10-05-6
Safety
Illuminate Work Area Safely

Illuminate your work area adequately but safely. Use
a portable safety light for working inside or under the
machine. Make sure the bulb is enclosed by a wire cage.
The hot filament of an accidentally broken bulb can ignite
spilled fuel or oil.
Work In Ventilated Area

Engine exhaust fumes can cause sickness or death. If
it is necessary to run an engine in an enclosed area,
remove the exhaust fumes from the area with an exhaust
pipe extension.
If you do not have an exhaust pipe extension, open the
doors and get outside air into the area.
Remove Paint Before Welding or Heating

Avoid potentially toxic fumes and dust.
Hazardous fumes can be generated when paint is heated
by welding, soldering, or using a torch.
Remove paint before heating:
• Remove paint a minimum of 100 mm (4 in.) from area
to be affected by heating. If paint cannot be removed,
wear an approved respirator before heating or welding.
• If you sand or grind paint, avoid breathing the dust.
Wear an approved respirator.
• If you use solvent or paint stripper, remove stripper with
soap and water before welding. Remove solvent or
paint stripper containers and other flammable material
Do all work in an area that is well ventilated to carry toxic
from area. Allow fumes to disperse at least 15 minutes
fumes and dust away.
before welding or heating.
Dispose of paint and solvent properly.
Do not use a chlorinated solvent in areas where welding
will take place.
10-05-7
Safety
Avoid Harmful Asbestos Dust

Avoid breathing dust that may be generated when
handling components containing asbestos fibers. Inhaled
asbestos fibers may cause lung cancer.
Components in products that may contain asbestos
fibers are brake pads, brake band and lining assemblies,
clutch plates, and some gaskets. The asbestos used in
these components is usually found in a resin or sealed in
some way. Normal handling is not hazardous as long as
airborne dust containing asbestos is not generated.
Avoid creating dust. Never use compressed air for
cleaning. Avoid brushing or grinding material containing
asbestos. When servicing, wear an approved respirator.
A special vacuum cleaner is recommended to clean Keep bystanders away from the area.
asbestos. If not available, apply a mist of oil or water on
the material containing asbestos.
Service Tires Safely

Explosive separation of a tire and rim parts can cause
serious injury or death.
Do not attempt to mount a tire unless you have the proper
equipment and experience to perform the job.
Always maintain the correct tire pressure. Do not inflate
the tires above the recommended pressure. Never weld
or heat a wheel and tire assembly. The heat can cause
an increase in air pressure resulting in a tire explosion.
Welding can structurally weaken or deform the wheel.
When inflating tires, use a clip-on chuck and extension
hose long enough to allow you to stand to one side and
NOT in front of or over the tire assembly. Use a safety
cage if available.
Check wheels for low pressure, cuts, bubbles, damaged
rims or missing lug bolts and nuts.
10-05-8
Safety
Stay Clear of Rotating Drivelines

Entanglement in rotating driveline can cause serious
injury or death.
Keep driveline shields in placeat all times. Make sure
rotating shields turn freely.
Wear close fitting clothing. Stop the engine and be sure
that PTO driveline is stopped before making adjustments,
connections, or cleaning out PTO driven equipment.
Do not install any adapter device that results in a portion of

the rotating implement shaft to be unguarded.
Service Cooling System Safely

Explosive release of fluids from pressurized cooling
system can cause serious burns.
Shut off engine. Only remove filler cap when cool enough
to touch with bare hands. Slowly loosen cap to first stop
to relieve pressure before removing completely.
10-05-9
Safety
Dispose of Waste Properly

Improperly disposing of waste can threaten the
environment and ecology. Potentially harmful waste used
with Oreion Motors equipment include such items as oil,
fuel,coolant, brake fluid, filters, and batteries.
Use leakproof containers when draining fluids. Do not use
food or beverage containers that may mislead someone
into drinking from them.
Do not pour waste onto the ground, down a drain, or into
any water source.
Air conditioning refrigerants escaping into the air can
damage the Earth’s atmosphere. Government regulations
may require a certified air conditioning service center to
recover and recycle used air conditioning refrigerants.
Inquire on the proper way to recycle or dispose of waste
from your local environmental or recycling center, or from
your Oreion Motors dealer.
Handle Chemical Products Safely

Direct exposure to hazardous chemicals can cause
serious injury. Potentially hazardous chemicals used with
Oreion Motors equipment include such items as
lubricants, coolants, paints, and adhesives.
A Material Safety Data Sheet (MSDS) provides specific
details on chemical products: physical and health hazards,
safety procedures, and emergency response techniques.
Check the MSDS before you start any job using a
hazardous chemical. That way you will know exactly what
the risks are and how to do the job safely. Then follow
procedures and recommended equipment.
(See your Oreion Motors dealer for MSDS’s on
chemical products used with Oreion Motors
equipment.)
Live With Safety

Before returning machine to customer, make sure
machine is functioning properly, especially the safety
systems. Install all guards and shields.
10-05-10
Section 20
Specifications
Contents
Page
Metric Bolt and Screw Torque
Values ........................................................ 20-05-1
Unified Inch Bolt and Screw Torque
Values ........................................................ 20-05-2
Group 10—O-Ring Seal Service Recommendations

Face Seal Fittings With Inch Stud
Ends Torque .............................................. 20-10-1
Face Seal Fittings With Metric Stud
Ends Torque .............................................. 20-10-2
Service Recommendations for Fittings
Flat Face O-Ring Seal...............................20-10-3
Service Recommendations for
O-Ring Boss Fittings.................................. 20-10-3
Metric Cap Screw Torque
Values—Grade 7 ....................................... 20-10-4

Gasoline ........................................................ 20-15-1
Gasoline Storage........................................... 20-15-2
4 - Cycle Gasoline Engine Oil........................ 20-15-2
Break-In Engine Oil - 4-Cycle
Gasoline .................................................... 20-15-3
Transaxle Oil ................................................. 20-15-4
FWD Differential Oil.... ................................. 20-15-4
Alternative Lubricants .................................... 20-15-4
Synthetic Lubricants ...................................... 20-15-4
Lubricant Storage .......................................... 20-15-5
Mixing of Lubricants....................................... 20-15-5
Oil Filters ....................................................... 20-15-5
Brake Fluid .................................................... 20-15-5
Chassis Grease ............................................. 20-15-5
Group 20—Coolant
Recommended Engine Coolant..................... 20-20-1
20-1
Group 05
Specifications
Metric Bolt and Screw Torque Values
4.8 8.8 9.8 10.9 12.9 12.9
4.8 8.8 9.8 10.9 12.9 12.9
Bolt or Screw Class 4.8 Class 8.8 or 9.8 Class 10.9 Class 12.9
Size Lubricateda Dryb Lubricateda Dryb Lubricateda Dryb Lubricateda Dryb
N·m lb.-in. N·m lb.-in. N·m lb.-in. N·m lb.-in. N·m lb.-in. N·m lb.-in. N·m lb.-in. N·m lb.-in.
M6 4.7 42 6 53 8.9 79 11.3 100 13 115 16.5 146 15.5 137 19.5 172
N·m lb.-ft. N·m lb.-ft. N·m lb.-ft. N·m lb.-ft.
M8 11.5 102 14.5 128 22 194 27.5 243 32 23.5 40 29.5 37 27.5 47 35
N·m lb.-ft. N·m lb.-ft. N·m lb.-ft.
M10 23 204 29 21 43 32 55 40 63 46 80 59 75 55 95 70
N·m lb.-ft.
M12 40 29.5 50 37 75 55 95 70 110 80 140 105 130 95 165 120
M14 63 46 80 59 120 88 150 110 175 130 220 165 205 150 260 190
M16 100 74 125 92 190 140 240 175 275 200 350 255 320 235 400 300
M18 135 100 170 125 265 195 330 245 375 275 475 350 440 325 560 410
M20 190 140 245 180 375 275 475 350 530 390 675 500 625 460 790 580
M22 265 195 330 245 510 375 650 480 725 535 920 680 850 625 1080 800
M24 330 245 425 315 650 480 820 600 920 680 1150 850 1080 800 1350 1000
M27 490 360 625 460 950 700 1200 885 1350 1000 1700 1250 1580 1160 2000 1475
M30 660 490 850 625 1290 950 1630 1200 1850 1350 2300 1700 2140 1580 2700 2000
M33 900 665 1150 850 1750 1300 2200 1625 2500 1850 3150 2325 2900 2150 3700 2730
M36 1150 850 1450 1075 2250 1650 2850 2100 3200 2350 4050 3000 3750 2770 4750 3500
Torque values listed are for general use only, based on the strength of Shear bolts are designed to fail under predetermined loads. Always
the bolt or screw. DO NOT use these values if a different torque value or replace shear bolts with identical property class. Replace fasteners with
tightening procedure is given for a specific application. For stainless steel the same or higher property class. If higher property class fasteners are
fasteners or for nuts on U-bolts, see the tightening instructions for the used, tighten these to the strength of the original. Make sure fastener
specific application. Tighten plastic insert or crimped steel type lock nuts threads are clean and that you properly start thread engagement. When
by turning the nut to the dry torque shown in the chart, unless different possible, lubricate plain or zinc plated fasteners other than lock nuts,
instructions are given for the specific application. wheel bolts or wheel nuts, unless different instructions are given for the
specific application.
a
“Lubricated” means coated with a lubricant such as engine oil, fasteners with phosphate and oil coatings, or M20
and larger fasteners with zinc flake coating.
b
“Dry” means plain or zinc plated without any lubrication, or M6 to M18 fasteners with zinc flake coating.
20-05-1
Specifications
Unified Inch Bolt and Screw Torque Values
Bolt or Screw SAE Grade 1 SAE Grade 2a SAE Grade 5, 5.1 or 5.2 SAE Grade 8 or 8.2
Size Lubricatedb Dryc Lubricatedb Dryc Lubricatedb Dryc Lubricatedb Dryc
N·m lb.-in. N·m lb.-in. N·m lb.-in. N·m lb.-in. N·m lb.-in. N·m lb.-in. N·m lb.-in. N·m lb.-in.
1/4 3.7 33 4.7 42 6 53 7.5 66 9.5 84 12 106 13.5 120 17 150
N·m lb.-ft. N·m lb.-ft.
5/16 7.7 68 9.8 86 12 106 15.5 137 19.5 172 25 221 28 20.5 35 26
N·m lb.-ft. N·m lb.-ft.
3/8 13.5 120 17.5 155 22 194 27 240 35 26 44 32.5 49 36 63 46
N·m lb.-ft. N·m lb.-ft. N·m lb.-ft.
7/16 22 194 28 20.5 35 26 44 32.5 56 41 70 52 80 59 100 74
N·m lb.-ft.
1/2 34 25 42 31 53 39 67 49 85 63 110 80 120 88 155 115
9/16 48 35.5 60 45 76 56 95 70 125 92 155 115 175 130 220 165
5/8 67 49 85 63 105 77 135 100 170 125 215 160 240 175 305 225
3/4 120 88 150 110 190 140 240 175 300 220 380 280 425 315 540 400
7/8 190 140 240 175 190 140 240 175 490 360 615 455 690 510 870 640
1 285 210 360 265 285 210 360 265 730 540 920 680 1030 760 1300 960
1-1/8 400 300 510 375 400 300 510 375 910 670 1150 850 1450 1075 1850 1350
1-1/4 570 420 725 535 570 420 725 535 1280 945 1630 1200 2050 1500 2600 1920
1-3/8 750 550 950 700 750 550 950 700 1700 1250 2140 1580 2700 2000 3400 2500
1-1/2 990 730 1250 930 990 730 1250 930 2250 1650 2850 2100 3600 2650 4550 3350
Torque values listed are for general use only, based on the strength of the bolt Replace fasteners with the same or higher grade. If higher
or screw. DO NOT use these values if a different torque value or tightening grade fasteners are used, tighten these to the strength of the
procedure is given for a specific application. For plastic insert or crimped steel original. Make sure fastener threads are clean and that you
type lock nuts, for stainless steel fasteners, or for nuts on U-bolts, see the properly start thread engagement. When poss ble, lubricate
tightening instructions for the specific application. Shear bolts are designed to fail plain or zinc plated fasteners other than lock nuts, wheel bolts
under predetermined loads. Always replace shear bolts with identical grade. or wheel nuts, unless different instructions are given for the
specific application.
a
Grade 2 applies for hex cap screws (not hex bolts) up to 6 in. (152 mm) long. Grade 1 applies for hex cap screws over 6
in. (152 mm) long, and for all other types of bolts and screws of any length.
b
“Lubricated” means coated with a lubricant such as engine oil, fasteners with phosphate and oil coatings, or 7/8 in.
and larger fasteners with zinc flake coating.
c
“Dry” means plain or zinc plated without any lubrication, or 1/4 to 3/4 in. fasteners with zinc flake coating.
20-05-2
Group 10
O-Ring Seal Service Recommendations
Face Seal Fittings With Inch Stud Ends Torque
Nominal Tube OD/Hose ID Face Seal Tube/Hose End O-Ring Stud Ends
Metric Inch Tube OD Thread Tube Nut/Swivel Nut Bulkhead Lock Nut Thread Straight Fitting or
Tube OD Size Torque Torque Size Lock Nut Torque
mm Dash Size in. mm in. N•m lb-ft N•m lb-ft in. N•m lb-ft
5 -3 0.188 4.76 3/8-24 8 6
6 -4 0.250 6.35 9/16-18 16 12 12 9 7/16-20 12 9
8 -5 0.312 7.94 1/2-20 16 12
10 -6 0.375 9.52 11/16-16 24 18 24 18 9/16-18 24 18
12 -8 0.500 12.70 13/16-16 50 37 46 34 3/4-16 46 34
16 -10 0.625 15.88 1-14 69 51 62 46 7/8-14 62 46
19 -12 0.750 19.05 1-3/16-12 102 75 102 75 1-1/16-12 102 75
22 -14 0.875 22.22 1-3/16-12 102 75 102 75 1-3/16-12 122 90
25 -16 1.000 25.40 1-7/16-12 142 105 142 105 1-5/16-12 142 105
32 -20 1.25 31.75 1-11/16-1 190 140 190 140 1-5/8-12 190 140
2
38 -24 1.50 38.10 2-12 217 160 217 60 1-7/8-12 217 160
20-10-1
Face Seal Fittings With Metric Stud Ends Torque
Nominal Tube OD/Hose ID Face Seal Tube/Hose End O-Ring Stud Ends, Straight Fitting, or Lock Nut
Metric Inch Tube OD Thread Tube Nut/Swivel Nut Bulkhead Lock Thread Hex Steel or Gray Aluminum
Tube Size Torque Nut Torque Size Size Iron Torque Torque
OD
mm Dash in. mm in. mm N•m lb-ft N•m lb-ft in. mm N•m lb-ft N•m lb-ft
Size
6 -4 0.250 6.35 9/16-1 17 16 12 12 9 M12X1 17 21 15.5 9 6.6
8 .5
8 -5 0.312 7.94
M14X1 19 33 24 15 11
.5
10 -6 0.375 9.52 11/16-1 22 24 18 24 18 M16X1 22 41 30 18 13
6 .5
12 -8 0.500 12.70 13/1 24 50 37 46 34 M18X1 24 50 37 21 15
6-16 .5
16 -10 0.625 15.88 1-14 30 69 51 62 46 M22X1 27 69 51 28 21
.5
-12 0.750 19.05 1-3/1 36 102 75 102 75 M27X2 32 102 75 46 34
6-12
22 -14 0.875 22.22 1-3/1 36 102 75 102 75 M30X2 36
6-12
25 -16 1.000 25.40 1-7/1 41 142 105 142 105 M33X2 41 158 116 71 52
6-12
28 M38X2 46 176 130 79 58
32 -20 1.25 31.75 1-11/1 50
6-12
-24
20-10-2
Service Recommendations For Flat Face

O-Ring Seal Fittings
1. Inspect the fitting sealing surfaces. They must be free
of dirt or defects.
2. Inspect O-ring. It must be free of damage or defects.
3. Lubricate O-rings and install into groove using
petroleum jelly to hold in place.
4. Push O-ring into the groove with plenty of petroleum
jelly so O-ring is not displaced during assembly.
5. Index angle fittings and tighten by hand, by pressing
joint together to insure O-ring remains in place.
6. Tighten fitting or nut to torque value shown on the
chart per dash size stamped on the fitting. Do not
allow hoses to twist when tightening fittings.
FLAT FACE O-RING SEAL FITTING TORQUEa
Tube Size Dash Size Thread Size Swivel Nut Torque Bulkhead Nut Torque
Outside Diameter
mm (in.) in. N•m (lb-ft) N•m (lb-ft)
6.35 (1/4) -4 9/16-18 16 (12) 5 (3.5)
9.52 (3/8) -6 11/16-16 24 (18) 9 (6.5)
12.70 (1/2) -8 13/16-16 50 (37) 17 (12.5)
15.88 (5/8) -10 1-14 69 (51) 17 (12.5)
19.05 (3/4) -12 1-3/16-12 102 (75) 17 (12.5)
22.22 (7/8) -14 1-3/16-12 102 (75) 17 (12.5)
25.40 (1) -16 1-7/16-12 142 (105) 17 (12.5)
31.75 (1-1/4) -20 1-11/16-12 190 (140) 17 (12.5)
38.10 (1-1/2) -24 2-12 217 (160) 17 (12.5)
The torque values shown are based on lubricated connections as in reassembly.
Service Recommendations for O-Ring Boss

Fittings
STRAIGHT FITTING
1. Inspect O-ring boss seat for dirt or defects.
2. Lubricate O-ring with petroleum jelly. Place electrical
tape over threads to protect O-ring. Slide O-ring over
tape and into O-ring groove of fitting. Remove tape.
3. Tighten fitting to torque value shown on chart.
Continued on next page
20-10-3
ANGLE FITTING
1. Back-off lock nut (A) and back-up washer (B)
completely to head-end (C) of fitting.
2. Turn fitting into threaded boss until back-up washer
contacts face of boss.
3. Turn fitting head-end counterclockwise to proper index
(maximum of one turn).
4. Hold fitting head-end with a wrench and tighten locknut
and back-up washer to proper torque value.
NOTE: Do not allow hoses to twist when tightening fittings.
TORQUE VALUE
Thread Size N·m lb-ft
3/8-24 UNF 8 6
7/16-20 UNF 12 9
1/2-20 UNF 16 12
9/16-18 UNF 24 18
3/4-16 UNF 46 34
7/8-14 UNF 62 46
1-1/16-12 UN 102 75
1-3/16-12 UN 122 90
1-5/16-12 UN 142 105
1-5/8-12 UN 190 140
1-7/8-12 UN 217 160
NOTE: Torque tolerance is ± 10%.
Size N•m (lb-ft)

Metric Cap Screw Torque Values—Grade 7
M6 9.5—12.2 (7—9)
NOTE: When bolting aluminum parts, tighten to 80% M8 20.3—27.1 (15—20)
of torque specified in table.
M10 47.5—54.2 (35—40)
M12 81.4—94.9 (60—70)
M14 128.8—146.4 (95—108)
M16 210.2—240 (155—177)
20-10-4
Group 15
General Information
Gasoline
4 - Cycle Engines
CAUTION: Avoid Injury! Gasoline is HIGHLY

FLAMMABLE, handle it with care. DO NOT refuel
machine while: indoors, always fill gas tank
outdoors; machine is near an open flame or
sparks; engine is running, STOP engine; engine
is hot, allow it to cool sufficiently first; smoking.
Help prevent fires: fill gas tank to bottom of
filler neck only; be sure fill cap is tight after
fueling; clean up any gas spills IMMEDIATELY;
keep machine clean and in good repair - free of
excess grease, oil, debris, and faulty or damaged
parts; any storage of machines with gas left in
tank should be in an area that is well ventilated
to prevent possible igniting of fumes by an open
flame or spark, this includes any appliance with a
pilot light. To prevent fire or explosion caused by
STATIC ELECTRIC DISCHARGE during fueling:
ONLY use a clean, approved POLYETHYLENE
PLASTIC fuel container and funnel WITHOUT
any metal screen or filter.
To avoid engine damage:

• DO NOT mix oil with gasoline;
• fill gas tank at the end of each day's operation to help

prevent condensation from forming inside a partially
filled tank;
• keep up with specified service intervals.
Use of alternative oxygenated, gasohol blended, unleaded
gasoline is acceptable as long as:
• the ethyl or grain alcohol blends DO NOT exceed 10%
by volume or
• methyl tertiary butyl ether (MTBE) blends DO NOT
exceed 15% by volume
RFG (reformulated) gasoline is acceptable for all
machines designed for use of regular unleaded fuel. Older
machines (that were designed for leaded fuel) may see
some accelerated valve and seat wear.
IMPORTANT: Avoid Damage! California Proposition
65 Warning: Gasoline engine exhaust from
this product contains chemicals known to
the State of California to cause cancer, birth
defects, or other reproductive harm.
20-15-1
General Information
Break-In Engine Oil - 4-Cycle Gasoline

IMPORTANT: Avoid Damage! ONLY use a quality
break-in oil in rebuilt or remanufactured engines
for the first 200 miles (maximum) of operation.
DO NOT use oils with heavier viscosity weights
than SAE 5W-30 or oils meeting specifications
API SG or SH, these oils will not allow rebuilt or
remanufactured engines to break-in properly.
The following oil is PREFERRED:

• BREAK - IN ENGINE OIL.
BREAK - IN ENGINE OIL is formulated withspecial
additives for aluminum and cast iron type enginesto allow
the power cylinder components (pistons, rings,
and liners as well) to “wear-in” while protecting other
engine components, valve train and gears, from abnormal
wear. Engine rebuild instructions should be followed
closely to determine if special requirements are
necessary.
The following Oreion Motors oil is also recommended:

•SAE 5W-30.
If the above recommended oils are not available, use
abreak-in engine oil meeting the followingspecification
during the first 200 miles (maximum) ofoperation:
• SAE 5W-30 - API Service Classification SE or higher.

IMPORTANT: Avoid Damage! After the break-in
period, use the Oreion Motors oil that is
recommended for this engine.
20-15-3
General Information
Lubricant Storage dust, moisture, and other contamination. Store drums on

their sides. Make sure all containers are properly marked
All machines operate at top efficiency only when clean as to their contents. Dispose of all old, used containers
lubricants are used. Use clean storage containers to and their contents properly.
handle all lubricants. Store them in an area protected from
Mixing of Lubricants requirements. Mixing different lubricants can interfere with

the proper functioning of these additives and lubricant
In general, avoid mixing different brands or types properties which will downgrade their intended specified
of lubricants. Manufacturers blend additives in their performance.
lubricants to meet certain specifications and performance
Oil Filters
Most Oreion Motors filters contain pressure relief
IMPORTANT: Avoid Damage! Filtration of oils is and anti-drainback valves for better engine
critical to proper lubrication performance. protection.
Always change filters regularly.
Other oil filters may be used if above recommended
Oreion Motors oil filters are not available, provided
The following Oreion Motors oil filters are PREFERRED:
they meet the following specification:
• AUTOMOTIVE AND LIGHT TRUCK ENGINE OIL
FILTERS.
Brake Fluid
• DOT4 certified.
The following Oreion Motors heavy duty brake • Conforms to Motor Vehicle Safety Standard No. 116.
PREFERRED for all disc brakes: • Minimum wet boiling point 140°C (284°F).
• Brake Fluid - DOT4
• Minimum dry boiling point 232°C (450°F) to prevent
vapor lock.
Other brake fluids may be used if the above Oreion
Motors brake fluid is not available and they provide the
following:
Chassis Grease • Multi-Purpose HD Lithium Complex Grease

Use the following grease based on the air temperature
• Moly High-Temperature EP Grease
range. Operating outside of the recommended grease air Other greases may be used if above preferred Oreion
temperature range may cause premature failures. Motors grease is not available, provided they meet
the following specification:
The following Oreion Motors grease is PREFERRED:
• Multi-Purpose SD Polyurea Grease • Oreion Motors Standard Grade 2.
20-15-5
Group 20
Coolant
Recommended Engine Coolant COOL Premix is available in a concentration of
IMPORTANT: Avoid Damage! Using incorrect coolant 55% propylene glycol. Additional recommended
mixture can cause overheating and damage coolants:
to the radiator and engine:
Do not operate engine with plain water. • Concentrate in a 40% to 60% mixture of concentrate
with water.
Do not exceed a 50% mixture of coolant
and water.
Aluminum engine blocks and radiators require If the recommended coolants are unavailable, use
approved ethylene-glycol based coolant. an ethylene glycol or propylene glycol base coolant
that meets the following specification:
The engine cooling system is filled to provide year-round
protection against corrosion and cylinder liner pitting, and • predilute (50%) coolant.
winter freeze protection to -37 degrees C (-34 degrees F). • coolant concentrate i n a 40% to 60% mixture of
If protection at lower temperatures is required, consult concentrate with water.
your Oreion Motors dealer for recommendations. Check container label before using to be sure it has the
The following coolants are preferred: appropriate specifications for your machine. Use coolant
with conditioner or add conditioner to coolant before using.
• Oreion Motors COOL Premix Water Quality
• Water quality is important to the performance of the
COOL Premix are available in a concentration cooling system. Distilled, deionized, or demineralized
of 50% propylene glycol. water is recommended with ethylene glycol base engine
coolant concentrate.
20-20-1
20-25-1
Section 30
Engine – Gas
Contents
Page
Page
Specifications ................................................ 30-05-1 Check Connecting Rod Bearing
Essential or Recommended Tools.................. 30-05-5 Clearance ................................................ 30-25-45
Service Equipment and Tools ........................ 30-05-6 Check Connecting Rod Side Play................ 30-25-46
Other Material................................................ 30-05-8 Repair Piston and Connecting
Rod .......................................................... 30-25-46
Group 10—Component Location Repair Piston ............................................... 30-25-48
Engine Intake................................................. 30-10-1 Cylinder Bore............................................... 30-25-54
Engine Exhaust ............................................. 30-10-2 Remove and Install Crankshaft and
Engine Mounting............................................ 30-10-4 Main Bearings.......................................... 30-25-55
Coolant System ............................................. 30-10-6 Remove and Install Crankshaft
Engine Coolant Lines .................................... 30-10-7 Rear Oil Seal ........................................... 30-25-60
Engine Block and Head ................................. 30-10-8 Alternator Removal and
Engine Crankshaft and Pistons ................... 30-10-10 Installation ............................................... 30-25-62
Engine Valve Train....................................... 30-10-12 Starting Motor Removal and
Installation ............................................... 30-25-64
Group 15—Diagnostics Fuel Injector Replacement........................... 30-25-67
Starting Diagnosis .........................................30-15-1 Exhaust Gas Oxygen Sensor
Engine Performance Diagnosis .....................30-15-3 Replacement ........................................... 30-25-68
Engine Coolant Diagnosis .............................30-15-8 Knock Sensor Replacement ........................ 30-25-68
Fuel and Oil Diagnosis ..................................30-15-9 Camshaft Position Sensor
Replacement ........................................... 30-25-69
Group 20—Tests and Adjustments Crankshaft Position Sensor
Throttle Cable Adjustment ............................. 30-20-1 Replacement ........................................... 30-25-69
Idle Speed Check .......................................... 30-20-4 Intake Manifold Pressure/Tempera-
Fuel Pump/Regulator Pressure ture Sensor Replacement........................ 30-25-70
Test ............................................................ 30-20-4 Throttle Body Replacement ......................... 30-25-70
Cylinder Leak-Down Test............................... 30-20-6
Valve Clearance Adjustment ......................... 30-20-9
Oil Pressure Test ......................................... 30-20-11
Radiator Cap Pressure Test ........................ 30-20-12
Fill and Bleed Coolant System .................... 30-20-12
Thermostat Test........................................... 30-20-13
Group 25—Repair
Remove and Install Engine............................ 30-25-1
Remove and Install Valve Cover ................... 30-25-8
Timing Belt Removal and
Installation ................................................. 30-25-9
Remove and Install Cylinder
Head ........................................................ 30-25-15
Remove and Install Intake
Manifold ................................................... 30-25-22
Exhaust Manifold Removal and
Installation ............................................... 30-25-22
Recondition Cylinder Head.......................... 30-25-23
Remove and Install Oil Pan ......................... 30-25-28
Remove and Install Oil Pump ...................... 30-25-29
Remove and Install Crankshaft
Front Oil Seal........................................... 30-25-36
Remove and Install Camshafts.................... 30-25-38
Check Crankshaft Main Bearing
Clearance ................................................ 30-25-44
30-1
Group 05
Specifications
Specifications
Item Measurement Specification
Specifications:
Make Chery
Model SQR372
Type 4-cycle gas/Liquid Cooled
Cylinders 3
Bore 72 mm (2.835 in.)
Stroke 66.5 mm (2.618 in.)
Displacement 812 cm3 (49.5 cu-in.)
Spark Plug NGK BKR6 EGP

0.9 - 1.05 mm (0.035 - 0.041 in.)
Spark Plug Gap
2.2 L (2.3 qt)
Crankcase (approximate with filter)
Engine Oil (see temperature chart
in spec section, 5W - 30 Preferred)
Cooling system (Including recovery
tank)
Engine:
Rev Limiter Speed 6150 rpm
Maximum compression pressure 138 kPa (20 psi)
variation between cylinders
Radiator Cap
Maximum test pressure 117 kPa (17 psi)
Minimum pressure after 15 seconds 90 kPa (13 psi)
Minimum pressure 83 kPa (12 psi)
Cylinder Head:
Spark Plug Torque 20 N·m (177 lb-in.)
Spark Plug Insulator Top to Valve 39 mm (1.535 in.)
Head Height
Valves and Springs:
Valve Guide Top to Cylinder Head 13.71 mm (0.540 in.)
Height Intake
Exhaust 12.11 mm (0.477 in.)
Crankshaft:
End Play 0.089-0.211 mm (0.004 - 0.008 in.)
End Play Wear Limit 0.30 mm (0.012 in.)
Camshafts:
Oil Clearance Between Bearing 0.02 - 0.066 mm (0.001 - 0.003 in.)
Caps and Cam Journals
Piston:
Oil Ring 1.0 mm (0.039 in.)
30-05-1
Specifications

Cylinder Bore:
Out of Round 0.03 mm (0.001 in.)
Water Pump:
Cap Screw Torque 25 N·m (221 lb-in.)
Specifications:
Timing Belt Cover 6.1 N·m (53 lb-in.)
Timing Gear Bolt (Camshaft) 100 N·m (74 lb-ft)
Water Pump Body to Engine Bolts 25 N·m (221 lb-in.)
Maximum Slack in Throttle Cable Distance 1—3 mm (0.040—0.120 in.)
Throttle Cable Freeplay Distance 1—3 mm (0.039—0.118 in.)
Throttle Pedal to Stop Bolt Gap 1—1-1/2 mm (0.04—0.06 in.)
Low Idle Speed 950 ±50 rpm
Fuel Pressure 315—345 kPa (45.6—50.4 psi)
Valve Clearance
Intake Clearance 0.18 ± 0.05 mm (0.007 ± 0.002 in.)
Exhaust Clearance 0.25 ± 0.05 mm (0.010 ± 0.002 in.)
Valve Cover Bolt Torque Torque 6 N·m (53 lb-in.)
Oil Pressure 206—482 kPa (30—70 psi)
Radiator Cap Opening Pressure 76 kPa (11 psi)
Pressure―Minimum
Radiator Cap Opening Pressure 83—96 kPa (12—14 psi)
Pressure―Maximum
Thermostat Specifications
Begin-to-Open Temperature Approximately 82°C (180°F)
Full-Open Temperature Approximately 96°C (205°F)
Engine Mount to Engine Block Torque 73 N·m (54 lb-ft)
M10 Cap Screw
Engine Mount to Engine Block M8 Torque 37 N·m (27 lb-ft)
Cap Screw on Rear Mount
Rear Engine Mounting Isolator Torque 170 N·m
to Carrier Bolt (125 lb-ft)
Front Engine Mounting Isolator Torque 108 N·m
to Carrier Nut (80 lb-ft)
Left Hand Engine Strut to Torque 37 N·m
Transmission Bolts (27 lb.-ft.)
Left Hand Engine Strut to Engine Torque 73 N·m
Backing Plate Nuts (54 lb-ft)
Flywheel Bolts Torque 80 N·m (60 lb-ft)
30-05-2
Specifications
Exhaust Pipe to Manifold Nut Torque Torque 73 N·m (54 lb-ft)

Valve Cover Bolt Torque 6 N·m (53 lb-in.)
Timing Belt Tensioner to Water Gap 5 mm (0.2 in.)
Pump Housing
Tensioner Bolt Torque 25 N·m (18 lb-ft)
Finger Pressure Applied to Belt Pressure 20—30 N (4—6 lb)
at Mid-Point Between Cam and
Crack Sprockets
Timing Belt Deflection 5 mm (0.2 in.)
Timing Belt Tensioner Bolt Torque 25 N·m (18 lb-ft)
Crankshaft Pulley Bolt Torque 98 N·m (72 lb-ft)
Driveshaft Bearing Bolts Torque 73 N·m (54 lb-ft)
Cylinder Head Bolts
Initial Pass Torque 30 N·m (22 lb-ft)
Second Pass Torque 50 N·m (37 lb-ft)
Final Pass Torque 70 N·m (51 lb-ft)
Intake Manifold Cap Screw Torque 6 N·m (53 lb-in.)
Exhaust Manifold to Cylinder Torque 15 N·m (133 lb-in.)
Head Nuts
Exhaust Manifold to Exhaust Torque 73 N·m (54 lb-ft)
Pipe Nuts
Cylinder Flatness Distortion Distance 0.08 mm (0.003 in.)
Intake Valve Face Margin Thickness 0.8—1.2 mm (0.031—0.047 in.)
Exhaust Valve Face Margin Thickness 0.8—1.2 mm (0.031—0.047 in.)
Valve Face Margin Wear Limit Thickness 0.75 mm (0.030 in.)
Intake Valve Face Angle 45°
Exhaust Valve Face Angle 45°
“C” Distance 35 mm (1.378 in.)
Intake Valve Stem Diameter 4.96—4.98 mm (0.195—0.196 in.)
Exhaust Valve Stem Diameter 4.95—4.97 mm (0.195—0.196 in.)
Intake Valve Guide Diameter 5.00—5.018 mm (0.197—0.198 in.)
Exhaust Valve Guide Diameter 5.00—5.018 mm (0.197—0.198 in.)
Intake Valve Guide-to-Valve Stem Clearance 0.030—0.060 mm (0.001—0.002 in.)
Exhaust Valve Guide-to-Valve Stem Clearance 0.030—0.068 mm (0.001—0.003 in.)
Valve Spring Free Length (Nominal) Height 37 mm (1.457 in.)
Maximum Spring Inclination Distance 1.2 mm (0.047 in.)
Intake Valve Seat Width Distance NA
Exhaust Valve Seat Width Distance NA
Oil Pan Cap Screw Torque 6 N·m (53 lb-in.)
30-05-3
Specifications
Oil Pan Capacity 2.2 L (2.3 qt.)

Oil Pump Mounting Cap Screws Torque 20 N·m (177 lb in.)
Oil Pickup Tube Cap Screw Torque 6.1 N·m (53 lb-in.)
Outer Rotor-to-Pump Body Clearance 0.10—0.181 mm (0.004—0.007 in.)
Outer Rotor-to-Pump Body Clearance 0.25 mm (0.010 in.)
Wear Limit
Inner Rotor-to-Outer Rotor Clearance 0.05—0.18 mm (0.002—0.007 in.)
Inner Rotor-to-Outer Rotor Clearance 0.35 mm (0.014 in.)
Wear Limit
Crankshaft Pulley Cap Screw Torque 98 N•m (72 lb-ft)
Timing Belt Tensioner Cap Screw Torque 25 N•m (18 lb-ft)
Intake Camshaft End Play 0.1—0.17 mm (0.004—0.007 in.)
Exhaust Camshaft End Play 0.1—0.173 mm (0.004—0.007 in.)
Camshaft End Play (Max) End Play 0.18 mm (0.007 in.)
Camshaft Bearing Cap Screw Torque 9 ± 1 N·m
(80 ± 9 lb.-in.)
Front Camshaft Housing Bolts Torque NA
Camshaft Sprocket Bolt Torque NA
Intake Cam Front Journal Diameter 25.97 mm (1.022 in.)
Intake Cam 2, 3 & 4th Journals Diameter 22.97 mm (0.904 in.)
Exhaust Cam Front Journal Diameter 29.967 mm (1.18 in.)
Exhaust Cam 2, 3 & 4th Journals Diameter 22.967 mm (0.904 in.)
Main Bearing Cap Screw Torque 78 N·m (58 lb-ft)
Crankshaft Main Bearing Clearance 0.020—0.072 mm (0.0008—0.0028 in.)
Crankshaft Main Bearing Wear Limit Clearance 0.15 mm (0.006 in.)
Connecting Rod Cap Screw Torque 40 N·m (30 lb-ft)
Connecting Rod Bearing Oil Clearance 0.020—0.044 mm (0.001—0.002 in.)
Connecting Rod Bearing Wear Limit Clearance 0.07 mm (0.003 in.)
Connecting Rod Side Play End Play 0.15—0.24 mm (0.006—0.009 in.)
Connecting Rod Side Play―Wear End Play 0.30 mm (0.012 in.)
Limit
Connecting Rod Nut Torque 40 N·m (30 lb-ft)
Connecting Rod Bearing
Clearance
Connecting Rod Bearing Clearance 0.020—0.044 mm (0.0008—0.002 in.)
Connecting Rod Bearing Wear Clearance 0.07 mm (0.003 in.)
Limit
Crankshaft Connecting Rod Journal Diameter 36.984—37 mm (1.456—1.457 in.)
30-05-4
Specifications

Piston Ring Groove Side
Clearance
Top Piston Ring Clearance 0.03—0.06 mm (0.001—0.002 in.)
Top Piston Ring (Max) Clearance 0.12 mm (0.005 in.)
Second Piston Ring Clearance 0.03—0.06 mm (0.001—0.002 in.)
Second Piston Ring (Max) Clearance 0.11 mm (0.004 in.)
Piston Ring End Gap
Top Ring Gap 0.25—0.40 mm (0.010—0.016 in.)
Top Ring Wear Limit Gap 0.65 mm (0.026 in.)
Second Ring Gap 0.35—0.50 mm (0.014—0.020 in.)
Second Ring Wear Limit Gap 0.65 mm (0.026 in.)
Oil Control Ring Gap 0.20—0.070 mm (0.008—0.028 in.)
Oil Control Ring Wear Limit Gap 1.00 mm (0.075 in.)
Piston Pin Clearance
Piston Pin-to-Bore Clearance 0.004—0.009 mm (0.00015—0.00035
in.)
Piston Pin-to-Bore Wear Limit Clearance 0.015 mm (0.0006 in.)
Piston Diameter NA
Cylinder Bore (Max) Diameter 72.085 mm (2.838 in.)
Piston-to-Cylinder (Max) Clearance 0.10 mm (0.004 in.)
Main Bearing Cap Screws
First Pass Torque 24 N·m (18 lb-ft)
Second Pass Torque 48 N·m (36 lb-ft)
Final Pass Torque 70.5 N·m (52 lb-ft)
Crankshaft Radial Runout 0.03 mm (0.001 in.)
Crankshaft Main Bearing Journal Diameter 41.984—42 mm (1.653—1.654 in.)
Crankshaft Main Bearing Clearance 0.025—0.069 mm (0.001—0.003 in.)
Crankshaft Main Bearing Wear Limit Clearance 0.10 mm (0.004 in.)
Oil Seal Case Cap Screws Torque 25 N·m (221 lb-in.)
Flywheel Mounting Cap Screw Torque 83.4 N·m (62 lb-ft)
Essential or Recommended Tools RECOMMENDED TOOLS, as noted, are suggested to

perform the job correctly. Some tools may be available
from local suppliers or may be fabricated.
30-05-5
Specifications
Ridge Reamer ..................................................... Removes ridge from top of cylinder bore.
Piston Ring Compressor................................................NA Used to install pistons.
Service Equipment and Tools

NOTE: Order tools according to information given in service manual
Digital Pulse Tachometer...................................... Use to check idle speed.
400 kPa (60 psi) Pressure Gauge ........................ Used to check fuel pressure.
1/4 in. ID Fuel Hose and Hose Clamps........................N/A Connects gauge to test points.
Compression Leakdown Tester ........................... Check cylinder leakdown
Valve Shim Removal Tool.................................

Used to remove valve shims
Flat Feeler Gauge.........................................................N/A Check camshaft-to-valve actuator clearance

30-05-6
Specifications
Pressure Gauge Assembly................................... Connects pressure gauge to test point.

Check Engine Oil Pressure Connector .............................................................
Hose Assembly..................................................... Connects pressure gauge to test point.
Cooling System Pressure Pump.......................

Checks radiator cap operation.
Adaptor ................................................................. Connects radiator cap to pressure tester.
Thermostat Tester............................................
Check the operation of thermostat.
Valve Spring Compressor................................. Used to compress valve springs.
Valve Stem Seal Protector................................

Used to protect valve stem seals when installing on valve.
Intake Valve Seal Installer ................................

Use to install intake valve stem oil seals.
Exhaust Valve Seal Installer .............................

Used to install exhaust valve stem oil seals.
Oil Seal Protector .............................................

Used to protect oil seal.
Seal Installation Tool.....................................................

Used to install oil seals.
Socket...............................................................
Used to remove and install exhaust gas oxygen sensor.
30-05-7
Specifications
Other Material
Number Name Use
NA (U.S.) Pipe Sealant with Teflon Apply to threads of oil pressure switch.
NA (U.S.) Form-in-Place Gasket Applied to mating surfaces of oil

pan and engine block.
TY15130 (U.S.) Form-in-Place Gasket Applied to mating surfaces of

cylinder head.
Loctite 545 (U.S.) Apply to threads of camshaft

sprocket bolt.
NA (U.S.) Plastigage Used to check main bearing

clearances.
NA (U.S.) Plastigage® Used to measure main bearing

clearance.
NA (U.S.) Plastigage Used to check rod bearing clearances.
TY12130 (U.S.) Form-in-Place Gasket Sealer Apply to mating surface of engine

block for oil seal case
NA (U.S.) Form-in-Place Gasket Sealant Apply to transmission flange
30-05-8
Component Location
A—Gasket K—Gasket T— Cylinder Head AF—Bolt

B—Dowel Pin, Alignment L— Bolt (2 Used) U—Bracket AG—Gasket
C—Cylinder Block M—Clip V—Bolt (2 Used) AH—Oil Drain Plug
D—Pin, Alignment N—Housing W—O-Ring AI— Seal Washer
E—Bolt (6 Used) O—Seal X—Seal AJ—Bolt (16 used)
F— Oil Cap P—Head Bolt, Socket (8 Used) Y—Water Pump Assembly AK—Oil Pan
G—Screw (6 Used) Q—Washer (8 Used) Z— Bolt AL—Bolt
H—Cover R—Bolt (12 Used) AA—Bolt AM—Bolt
I— Valve Cover S—Camshaft Bearing Cap (3 AB—Pulley AN—Oil Pump Assembly
J— Seal (3 Used) Used) AC—Bolt (4 Used) AO—Pipe, Dipstick
AD—Bolt
AE—Seal
30-10-9
Component Location
Engine Crankshaft and Pistons
A—Piston Ring, Top (3 Used) G—Connecting Rod (3 Used) M—Gear, Belt U—Plate
B—Piston Ring, 2nd (3 Used) H—Rod Bearing Insert (6 Used) N—Guide Plate V—Bolt (5 Used)
C—Piston Ring Assembly, Oil (3 I— Thrust Bearing (2 Used) O—Vibration Dampener W—Seal, Rear Oil
Used) J— Crankshaft Bearing Insert (8 P—Bolt X—Flywheel
D—Piston (3 Used) Used) Q—Key Y—Pin, Locating (2 Used)
E—Piston Pin (3 Used) K—Crankshaft R—Flange Nut (6 Used) Z— Bolt (6 Used)
F— Bolt (6 Used) L— Seal, Front Oil S—Connecting Rod Bearing Cap
(3 Used)
T— Pin, Locating (2 Used)
30-10-10
Component Location
A—Bolt (6 Used) N—Bolt, Flange Y—Lifter (12 Used) AG—Valve, Intake (6 Used)
B—Cover O—Timing Belt Z— Lock, Collet (24 Used)
C—Cover P—Tension Idler AA—Collar (12 Used)
D—Seal Q—Bolt (4 used) AB—Spring Retainer (12 Used)
E—Bolt (12 Used) R—Snap Ring AC—Spring, Valve (12 Used)
F— Camshaft Bearing Cap (3 S—Washer, Wave AD—Seal, Valve (12 Used)
Used) T— Sub Gear, Timing nonreusable
G—Pin U—Circlip AE—Washer (12 Used)
2
H—Camshaft, Exhaust V—Main Gear, Timing AF—Valve, Exhaust (6 Used)
I— Gear, Timing W—Camshaft, Intake
1
J— Coupling, Flange X—Shim
K—Hub Lock Nut
L— Seal
M—Sprocket, Timing Belt
1
Shim used is based on valve clearance.
2
Exhaust valve components (X through AD) are identical to intake
valve components except valve. Valve shims may vary.
30-10-13
Group 15
Diagnostics
Starting Diagnosis
Starting Diagnosis
Symptom Problem Solution
Engine Starting Problems Engine will not crank Battery weak or discharged.
Fusible link defective.
Check key switch or wiring.
Starter solenoid defective.
Starter motor defective.
Engine seized.
Engine will not start; spark plug wet Check spark plug gap and spark
(Refer to Electrical section).
Timing belt broken or has jumped time.
Engine is hard to start when cold. Improper viscosity engine oil.
System diagnostic light illuminated,

check code(s) and repair.
Engine cranks but will not start Battery weak or discharged.
Check spark (Refer to Electrical

section).
Weak or faulty spark plug(s).
Faulty high tension leads.
Faulty ignition coil(s).
Faulty electronic control unit.
Contaminated fuel or faulty fuel supply

system.
Defective fuel pump.
Clogged fuel line or filter.
Fuel tank vent line clogged.
Air filter restricted.
Timing belt broken or has jumped time.
Defective head gasket.
30-15-1
Diagnostics
Poor compression.
Worn piston/piston rings stuck or not

seated.
Worn cylinder bore.
Worn or burned valves, or improper

clearance.
30-15-2
Diagnostics
Engine Performance Diagnosis The engine will go into a “safe mode” which shuts
off the fuel to number three cylinder and greatly
Engine Performance Diagnosis reduces engine performance. For loss of
power/poor performance problems, connect
CAUTION: Avoid Injury! Engine radiator fluid is machine to Service OBD2 port and
extremely hot during operation. The radiator check for a fault code. Repair the cause before
fan may start to rotate at any time. Keep hands considering mechanical problems with the engine.
away from all moving parts when testing.
NOTE: When certain problems are detected by the ECU

the System diagnostic
Engine Performance Loss of power Low oil level.
Engine overheating.
Too much oil in crankcase.

Faulty ignition coil.

system.
Carbon deposits in combustion

chamber.
Carbon deposits in exhaust

pipe/muffler.
Improper fuel mixture.
Check and clean air cleaner.
Timing belt has jumped time.
Worn piston/piston rings/cylinder

bore(s).
30-15-3
Diagnostics

clearance.
Broken valve spring. Warped cylinder

head(s).
Defective head gasket. Poor

compression.
Engine will not attain full speed ECU error code shuts off fuel and
spark to number 3 cylinder. Refer to
the Electrical section for tests.
Engine runs erratically Lack of coolant.

section).

Throttle body flange loose or leaking

at gasket.
Throttle body and throttle shaft worn.

system.

clearance.

head.

compression.
Engine misses at high rpm Check spark (Refer to Electrical

section)
30-15-4
Diagnostics
Diagnostic fault light illuminated,

Warped cylinder head.

clearance.

head.

compression.
Engine misses at low rpm Air being drawn through throttle body
or intake manifold flanges.

section).

clearance.
Engine rpm low or engine stalls Drive clutch problem.
Battery weak or discharged.
Idle air control faulty or electrical

problem, check and repair.
30-15-5
Diagnostics
Engine speed unstable (surging) check code(s) and repair.
Mixture too lean.
Black, smoky exhaust Mixture too rich.
Check spark plug gaps and spark

Spark plug fouled black Mixture too rich.
Check spark plug gaps and spark

Spark plug burned white Improper heat range spark plug(s).
Check spark plug gap and spark

(Refer to Electrical section). Mixture
too lean.
Runs better without air cleaner check code(s) and repair. (Refer to
the Electrical section for tests.)
Mixture too rich. Check and clean air

cleaner.
Runs worse when warm check code(s) and repair.
Mixture too rich. Check and clean air

cleaner.
Engine backfires Check spark (Refer to Electrical

section).
Exhaust leak
30-15-6
Diagnostics
Intake valve burned or sticking.
Engine knocks Engine low on oil.
Excessive engine load/overheating.

system.
Mechanical failure/worn parts.
Engine overheats check code(s) and repair.
Lack of coolant.
Excessive engine load.
Electric cooling fan not working.
Alternator/water pump belt

loose/missing.
Defective radiator hose or clamp.
Improper or defective radiator cap.
Defective radiator.
Cracked or porous casting.
Damaged water pump seals.
Improperly installed thermostat.
Broken valve spring.

clearance.
30-15-7
Diagnostics
Engine Coolant Diagnosis fan may start to rotate at any time. Keep hands
away from all moving parts when testing.
Engine Coolant Diagnosis
CAUTION: Avoid Injury! Engine radiator fluid is

extremely hot during operation. The radiator
Engine coolant Coolant leakage Lack of coolant.
Improper or defective radiator cap.
Defective radiator hose or clamp.
Defective radiator.
Cracked or porous casting.
Engine overheating.
Damaged water pump seals.
Improperly installed gasket.
Cylinder head gasket leaking.
) 30-15-8
Diagnostics
Fuel and Oil Diagnosis mode” which shuts off the fuel to number three
cylinder and greatly reduces engine performance.
Fuel and Oil Diagnosis For loss of power/poor performance problems,
connect machine to Service OBD2 port and
NOTE: When certain problems are detected by the ECU check for a fault code. Repair the cause before
the engine then goes into a “safe considering mechanical problems with the engine.
Engine fuel and oil Excessive oil consumption Too much oil in crankcase.
Incorrect oil viscosity.
Worn valve stem(s), valve guide(s),

and/or valve stem seals.
Plugged oil ring groove.
Poor compression.

seated.
Worn cylinder bore(s).
Excessive fuel consumption Check spark (Refer to Electrical

section).
Faulty TMAP or EGO sensor (Refer to

Electrical section).
Weak or faulty spark plug(s)
Broken valve spring.

clearance.
Poor compression.
30-15-9
Diagnostics

seated.
Worn cylinder bore(s).
30-15-10
Tests and Adjustments
Throttle Cable Adjustment
Purpose:
To ensure that throttle cable is allowing adequate travel
for throttle lever to reach full open and slow idle positions.
Equipment:
• 1/2 in. Wrenches
Procedure:
1. Park machine safely. See Park Machine Safely.
2. Raise cargo box.
3. With accelerator pedal up, control lever should be
contacting stop screw (A). Stops (B) on the spring
loaded “knee joint” should be touching each other.
A—Stop Screw C—Throttle Cable
Deflect cable slightly with finger at (C) to check amount B—Stops
of slack in cable. The amount of slack in throttle cable
should not exceed specifications.
Specification
Maximum Slack
in Throttle
Cable—Distance..........................................1—3 mm (0.040—0.120 in.)
4. Place a heavy object (heavy enough to keep pedal

down on the pedal stop bolt) on the accelerator pedal
or have an assistant hold the accelerator pedal down
against the pedal stop bolt.
5. Press against “knee joint” of throttle lever (arrow) to
see if throttle lever moves any further.
6. If slack on cable is incorrect in idle position or throttle
lever does not go all the way to stop, adjust throttle
cable.
30-20-1
Adjust Throttle Cable:

1. With accelerator pedal up, control lever should be
contacting stop screw (A). Stops (B) on the spring
loaded “knee joint” should be touching each other.
Deflect cable slightly with finger at (C) to check
amount of slack in cable. If free play is not within
specifications, loosen nuts (D) and adjust until proper
freeplay is obtained.
Specification
Throttle Cable
Freeplay—Distance...................................... 1—3 mm (0.039—0.118 in.)
A—Stop Screw C—Throttle Cable

B—Stops D—Jam Nuts
30-20-2
Idle Speed Check Keep hands away from moving parts

Purpose: while adjusting.
To check that engine is running at proper low idle speed. Engine components are HOT. Be careful not to
The high idle speed can be checked but not adjusted. touch, especially the exhaust pipe or muffler,
while making adjustments. Wear protective
Equipment: eye glasses and clothing.
• Digital Pulse Tachometer (use with clip-on 3. Raise cargo box. Run engine at slow idle and check
antennae lead for accurate rpm readings) rpm with tachometer. Record reading.
Procedure: Specification
Low Idle—Speed.................................................................. 950 ±50 rpm
Results:
NOTE: Engine must be at operating temperature
for test. Run engine until the radiator fan • If the slow idle is to specification the procedure is
has come on at least once. complete.
• If slow idle is not within specification, check for throttle
2. Start and run engine until engine is at operating linkage damage, idle air control problem, vacuum leak,
temperature. or throttle stop screw misadjustment (tampering).
CAUTION: Avoid Injury!
Fuel Pump/Regulator Pressure Test

Purpose:
To check condition of fuel pump and fuel pressure
regulator which determines fuel pressure.
Test Equipment:
• 400 kPa (60psi) Pressure Gauge
• 1/4 in. ID Fuel Hose and Hose Clamp
Procedure:
2. Allow engine and exhaust system to cool.
CAUTION: Avoid Injury! Gasoline vapor is

explosive. Do not expose to spark or flame.
Serious personal injury can result.
Be prepared for spilling fuel. Wipe up
any fuel immediately.
3. Assemble a test gauge and fuel hose as shown.

30-20-4
Valve Clearance Adjustment

Purpose:
NOTE: Perform valve clearance adjustment when
the engine is COLD.
To check and adjust valve clearances for proper engine

operation.
Equipment:
• Valve Shim Removal Tool
• Flat Feeler Gauge
Procedure:
2. Remove valve cover.
NOTE: There are two intake and two exhaust valves for A—Camshaft Lobe B—Feeler Gauge
each cylinder. The intake camshaft is next to the
intake manifold (toward the rear of the machine) and
the exhaust camshaft is on the exhaust manifold adjusted by changing shim on valve actuator. Shims
side of head (toward front of machine). are available in sizes shown on chart.
Valve Clearance—Specification
3. Remove spark plugs. Intake—Clearance............................. 0.18 ± 0.05 mm (0.007 ± 0.002 in.)
4. Turn engine crankshaft in direction of rotation until Exhaust—Clearance......................... 0.25 ± 0.05 mm (0.010 ± 0.002 in.)
the high spots of the camshaft lobes for valves to be Available Valve Adj Shims (mm)
checked (A) are pointing up. 2.18 2.50
5. Use a flat feeler gauge (B) to check the clearance 2.24 2.56
between the camshaft and the valve actuator. Increase 2.30 2.62
or decrease blade thickness until a slight drag is felt 2.36 2.68
when moving blade between cam and actuator. Read 2.42 2.74
the number on the feeler gauge blade and record
2.46 2.80
valve clearance and location of valve.
6. Check clearance reading with specification. If
clearance is not within specification clearance must be
7. To adjust valve clearance, turn lifter with a small pick

or screwdriver until notch (C) is accessible.
C—Valve Adjuster Notch
30-20-9
LVAL22450 —UN—01MAY12
8. Turn engine crankshaft in direction of rotation until the
high points of the camshaft lobes are pressing valve
actuator down on the valve to be adjusted. Insert
(D) between camshaft and outside ofactuator bore.
Make sure tool is not going to contactadjustment
shim (E).
9. Turn engine again until high point of camshaft lobe is
away from shim. The tool will be holding down valve
actuator so the shim can be removed.
10. Use a small screwdriver or small pick and remove
shim as shown.
D- Shim Removal Tool E—Adjustment Shim
11. Shims have a number on bottom side indicating

thickness of shim. Read number as if there were a
decimal point after the first digit, in this case 2.34 mm
(0.092 in.).
12. Measure the shim with a micrometer or an accurate
calipers to double check thickness of shim.
NOTE: A shim with a lower number will result in more
valve clearance and a shim with a higher number
will result in less valve clearance.
13. To calculate what thickness shim you will need for a

valve add the thickness of the removed shim with the
valve clearance you measured, then subtract what
the valve clearance should be. Example: say you
measured 0.30 mm clearance on an intake valve, and
Valve Clearance—Specification
the shim shown above 2.34 mm was removed. Add
Intake—Clearance............................. 0.18 ± 0.05 mm (0.007 ± 0.002 in.)
0.30 mm + 2.34 mm+ 2.64 mm. Then subtract the
Exhaust—Clearance......................... 0.25 ± 0.05 mm (0.010 ± 0.002 in.)
desired valve clearance (which on an intake valve is
0.18 mm). So 2.64 mm - 0.18 mm = 2.46 mm. 16. Repeat procedure for all valves.
NOTE: Shims should be installed with numbers 17. Install valve cover and tighten bolts to specifications.
facing down toward valve.
Specification
Valve Cover Bolt
14. Replace the 234 shim with a 246 shim and recheck
Torque—Torque.............................................................. 6 N·m (53 lb-in.)
clearance.
15. Recheck valve clearance, note that clearance can be
±0.05 mm. Readjust if necessary.
30-20-10
Oil Pressure Test

Purpose:
To determine condition of lubrication system.
Equipment:
• Pressure Gauge Assembly
• Hose Assembly
• Connector
Procedure:
2. Check engine oil level, bring level to full mark.
3. Run engine at FAST idle until cooling fan starts.
4. STOP engine
CAUTION: Avoid Injury! Engine components A—Oil Pressure Switch Wiring

are HOT. Be careful not to touch, especially Lead
the exhaust pipe or muffler, while making
adjustments. Wear protective eye glasses
and clothing. 9. Install oil pressure switch and switch wiring lead.
Use Oreion Motors™ Pipe Sealant with TEFLON®
5. Disconnect oil pressure switch wiring lead (A). or equivalent, on switch threads.
6. Remove oil pressure switch. Results:
7. Install Connector and connect Hose If oil pressure is BELOW specifications, inspect or replace
Assembly and Pressure Gauge Assembly. the following:
IMPORTANT: Avoid Damage! If pressure reading
is below 69 kPa (10 psi), STOP ENGINE
• Oil for proper viscosity and type.
IMMEDIATELY and determine cause.
• Oil Filter
• Oil pressure relief valve for broken or worn spring
8. Run engine at 3000 RPM and check gauge. Oil
• Oil pressure relief valve for stuck or damaged valve.
pressure should be within specifications.
• Worn or damaged oil pump.
• Oil pump suction screen or oil passages plugged.
Specification • Excessive wear of connecting rod and main bearings.
Oil—Pressure................................................206—482 kPa (30—70 psi)
30-20-11
Thermostat Test
Purpose:
To ensure thermostat opening and closing at specified
temperatures.
Equipment:
• Thermostat Tester
Procedure:
1. Park machine safely.
2. Allow cooling system to completely cool BEFORE
testing.
NOTE: Be sure to wipe-up and wash-off any spilled
coolant immediately.
A—Hose Clamp C—Bolts (2 used)
3. Drain coolant. B—Thermostat Cover D—Thermostat Housing
4. Loosen hose clamp (A) and disconnect hose from

thermostat cover (B). Remove bolts (C) and thermostat
housing (D). 5. Remove thermostat.
CAUTION: Avoid Injury! DO NOT allow thermostat

or thermometer to rest against the side or
bottom of glass container when heating water.
Either may rupture if overheated.
6. Suspend the thermostat and a thermometer in a

container of water.
7. Heat and stir the water. Observe opening action
of thermostat and compare temperatures with
specifications.
Thermostat Specifications—Specification
Begin-to-
Open—Temperature.................................... Approximately 82°C (180°F)
Full-Open—Tempera-
ture.............................................................. Approximately 96°C (205°F)
8. Remove the thermostat and observe the closing action

as it cools.
Results:
• If thermostat fails to meet any of these specifications,
replace it.
30-20-13
Repair
30. Remove four bolts (ah) from the clutch stub shaft and
remove shaft.
ah— Bolt (4 Used)
31. Remove two bolts (ai) securing crankshaft position

sensor (aj) and remove sensor.
32. Remove bolts (ak) and remove flywheel.
ai— Bolt (2 Used) ak— Bolt (6 Used)

aj— Crankshaft Position
Sensor
33. Remove four cap screws (al) and remove backplate

from engine.
al— Cap Screw (4 Used)
30-25-5
Repair
34. Remove three bolts (am) from shift cable bracket and
move bracket aside.
35. Disconnect alternator wiring
36. Maneuver the electrical harness clear of the engine
and set aside.
37. Attach engine hoist to engine lifting brackets and raise
hoist enough to support engine when engine mounts
are removed.
am—Bolt (3 Used)
30-25-6
Repair
39. Remove engine isolator nut and bolt (ao).

40. Remove bolts (ap) securing engine mounts to the front
and rear of engine block.
41. Carefully raise engine from machine.
Installation
Installation is the reverse of removal.
1. Carefully lower engine into machine. Tighten engine
mounting cap screws to specifications.
Specification
Engine Mount to Engine
Block M10 Cap Screw
—Torque......................................................................... 73 N·m (54 lb-ft)
Engine Mount to Engine
Block M8 Cap Screw on ao— Engine Isolator Nut and ap— Bolt (4 Used)
Rear Mount—Torque...................................................... 37 N·m (27 lb-ft) Bolt
2. Install rear engine isolator bolt. Tighten to specification.

Specification Specification
Rear Engine Mounting Primary Clutch Mounting
Isolator to Carrier Cap Screw—Torque....................................................... 35 N·m (26 lb-ft)
Bolt—Torque................................................................................170 N·m Secondary Clutch
(125 lb-ft) Mounting Cap
Screw—Torque............................................................... 70 N·m (52 lb-ft)
3. Install front engine isolator bolt and nut. Tighten to
specification. 10. Install drive belt.
Specification
11. Install outer clutch enclosure.
Front Engine Mounting
Isolator to Carrier 12. Clean exhaust pipe and exhaust manifold flanges of
Nut—Torque................................................................................108 N·m any old gasket material. Install a new manifold gasket.
(80 lb-ft)
13. Install exhaust manifold flange bolts and nuts and
4. Install backplate to engine. tighten to specifications.
5. Install crankshaft position sensor. Specification
Exhaust Pipe to Manifold
6. Install transmission mount and bolt to backplate and Nut Torque—Torque....................................................... 73 N·m (54 lb-ft)
transmission.
14. Connect all engine wiring harness connectors.
Specification
Left Hand Engine 15. Attach throttle cable to throttle lever and adjust cable.
Strut to Transmission
Bolts—Torque................................................................................37 N·m 16. Connect coolant hoses. Check condition of hoses and
(27 lb.-ft.) replace as necessary.
Left Hand Engine Strut 17. Attach ground wire to engine bracket.
to Engine Backing Plate
Nuts—Torque................................................................................73 N·m 18. Attach battery positive (+) cable and solenoid exciter
(54 lb-ft) wire to starting motor solenoid.
7. Use medium strength thread locker on flywheel bolts 19. Connect fuel line.
and install flywheel. Tighten bolts to specifications.
NOTE: Oil level should be at full mark with the cap
Specification screwed tight while the engine is cold. To make sure
Flywheel Bolts—Torque.................................................. 80 N·m (60 lb-ft) level is correct, start engine and run at 4500 rpm for
one minute. Stop engine and check oil level.
8. Install inner clutch enclosure.
9. Install primary and secondary clutches and tighten to 20. Fill engine to proper level with oil of correct
specifications. specifications.
21. Fill coolant to correct level. See Fill and Bleed Coolant
System.
30-25-7
Repair
Timing Belt Removal and Installation

Removal
NOTE: Timing belt can be replaced with engine in the
machine. Some photos in this section are shown
with engine out for clarity of photo.

2. Disconnect negative (—) battery cable.
3. Remove two cap screws (A) and belt cover (B).
A—Cap Screw (2 Used) B—Belt Cover
4. Remove bolt (C) and slide coupler forward onto

driveshaft.
5. Remove bolts (D) and move driveshaft aside.
6. Loosen alternator bolts and loosen and remove
alternator belt.
7. Remove four bolts from water pump pulley (E) and
remove pulley.
E—Water Pump Pulley
8. Remove bolt (F) holding dipstick tube and remove

dipstick tube.
9. Remove bolt (G) securing crankshaft pulley and
remove pulley. Use a puller if necessary.
F— Bolt G—Bolt
30-25-9
Repair
10. Remove the upper (H) and lower (I) timing belt covers.
H—Upper Timing Belt Cover I— Lower Timing Belt Cover
TIMING BELT COVERS MAY VARY AND MAY BE CHANGED

WITHOUT NOTICE
11. Remove belt guide (J).
J— Belt Guide
30-25-10
Repair
12. Align timing marks (K) on crankshaft sprocket and oil

pump housing.
K—Timing Marks
13. With crankshaft timing marks aligned as in previous

step, camshaft sprocket mark (L) should be either
straight up and aligned with timing mark (M) or down
at the 6 o’clock position. If it is in the 6 o’clock position
turn crankshaft one revolution and line up all marks.
L— Camshaft Sprocket Mark M—Timing Mark
NOTE: If timing belt is broken turn camshaft sprocket

bolt with a wrench until marks (L) and (M) align,
then turn crankshaft until marks (K) align.
Do not pry on belt with a screwdriver or sharp tool if
you plan on reusing the belt. Belt damage will result.
14. Remove belt tensioner (N) and remove belt.
N—Belt Tensioner
30-25-11
Repair
Installation
NOTE: There are only a few cases in which an
old belt can be reused.
If the belt has:
• low hours on it.
• has not been contaminated with coolant or oil.
• has no cracks or evident wear.
• no cracked or missing teeth.
It may be reused. If there is any doubt about
the condition of the belt, replace it.
1. Inspect belt sprockets for wear or damage. Replace

sprockets if worn or damaged.
2. Inspect belt tensioner for wear or damage. Tensioner
should turn smoothly and quietly. Outside diameter of K—Timing Marks
tensioner wheel should be smooth and clean. If any
defects are found, replace tensioner.
3. Inspect camshaft and crankshaft oil seals for any sign
of leakage. Inspect water pump for leakage. Any leaks
should be repaired before installing a new belt.
4. Before installing the belt, align timing marks (K) on
crankshaft sprocket and oil pump housing.
5. Align cam sprocket timing mark (L) with timing mark

(M) on front cam bearing cover.
NOTE: Once timing belt has been installed, engine should
be turned only in a clockwise direction as viewed
from the front (timing belt) side of engine.
6. Install timing belt. Make sure all marks are still aligned
and right side of belt has little or no slack.
L— Cam Sprocket Timing Mark M—Timing Mark
30-25-12
Repair
7. Install tensioner and push tensioner arm in direction

of arrow until the gap between the belt tensioner
and the bottom of the water pump housing meets
specifications.
Specification
Timing Belt Tensioner
to Water Pump
Housing—Gap.................................................................... 5 mm (0.2 in.)
8. Tighten tensioner bolt to specifications.

Specification
Tensioner Bolt—Torque.................................................. 25 N·m (18 lb-ft)
9. Rotate crankshaft clockwise two turns and line up all

timing marks again.
10. Apply specified finger pressure to belt about halfway

between cam and crank sprockets (arrow). The belt
should deflect the specified distance with specifed
finger pressure applied. If it does not, loosen tensioner
bolt (O) and move tensioner arm (N) right for more
tension or left for less tension. When proper tension is
obtained tighten tensioner bolt to specifications.
Specification
Finger Pressure Applied
to Belt at Mid-Point
Between Cam and Crack
Sprockets—Pressure................................................. 20—30 N (4—6 lb)
Timing Belt—Deflection...................................................... 5 mm (0.2 in.)
Bolt—Torque................................................................... 25 N·m (18 lb-ft)
11. Install the belt guide (P) with the curved edge out.
N—Tensioner Arm P—Belt Guide

O—Tensioner Bolt
30-25-13
Repair
12. Install the upper (H) and lower (I) timing belt covers.
H—Upper Timing Belt Cover I— Lower Timing Belt Cover

TIMING BELT COVERS VARY AND MAY BE CHANGED WITH
NO NOTICE
13. Install dipstick tube and bolt (F).

14. Install crankshaft pulley and tighten bolt (G) to
specification.
Specification
Crankshaft Pulley
Bolt—Torque................................................................... 98 N·m (72 lb-ft)
F— Dipstick Tube and Bolt G—Crankshaft Pulley Bolt
30-25-14
Repair
8. Remove bolt (G) and slide coupler forward onto

driveshaft.
9. Remove bolts (H) from bearing support and move
driveshaft aside.
10. Loosen alternator bolts (I) and remove alternator belt.
11. Remove four bolts from water pump pulley (J) and
remove pulley.
G—Bolt I— Alternator Bolts (2 Used)

H—Bolt (2 Used) J— Water Pump Pulley Bolts (4
Used)
12. Remove bolt (K) holding dipstick tube and remove

dipstick tube.
13. Remove bolt (L) securing crankshaft pulley and
remove pulley. Use a puller if necessary.
K—Dipstick Tube and Bolt L— Crankshaft Pulley Bolt
30-25-16
Repair
14. Remove two bolts (M) securing coil pack to head and
remove coil pack.
15. Remove valve cover. See Remove and Install Valve
Cover.
M—Bolt (2 used)
16. Remove the upper (N) and lower (O) timing belt covers.
N—Upper Timing Belt Cover O—Lower Timing Belt Cover
30-25-17
Repair
17. Remove belt guide (P).
P—Belt Guide
IMPORTANT: Avoid Damage! Do not use a

screwdriver or any sharp edged tool to
pry belt off of sprockets.
18. Remove belt tensioner (F). Remove the timing belt.
F— Belt Tensioner
30-25-18
Repair
19. Remove camshaft sprocket bolt and washer (G) and

cam sprocket (H).
G—Sprocket Bolt and Washer H—Cam Sprocket
20. Remove five bolts (I) and the front cam housing (J).
I— Bolt (5 Used) J— Front Cam Housing
21. Install a 5 mm x 80 bolt (K) into the hole next to the

pinned hole on the intake camshaft to hold master and
slave gears in position.
K—5 mm x 80 Bolt
30-25-19
Repair
22. Loosen camshaft bearing cap bolts in the sequence

shown.
NOTE: The cam bearing caps are numbered two, three,

and four and have an arrow pointing toward the
gear end of camshaft. Caps must be installed in the
same position and direction as when removed.
23. Remove the cam bearing caps (L).
L— Cam Bearing Caps
IMPORTANT: Avoid Damage! There is pressure

from the valve springs on the camshafts.
Keep camshafts parallel with the cylinder
head when removing and be prepared for a
sudden release of spring pressure.
24. Lift intake (M), and exhaust (N), camshafts out of

cylinder head.
M—Intake Camshaft N—Exhaust Camshaft
30-25-20
Repair
25. Loosen and remove cylinder head bolts in the

sequence shown.
26. Pull head straight up from block.
27. Remove exhaust and intake manifolds. See Remove
and Install Intake Manifold and Exhaust Manifold
Removal and Installation.
28. Disassemble and inspect cylinder head and valves.
See Recondition Cylinder Head.
Installation
CAUTION: Avoid Injury! Use safety glasses when

using compressed air to blow out bolt holes.
1. Clean all threads in top of cylinder block with a flat

bottom tap and blow debris from hole.
2. Clean any old gasket material from cylinder block and
cylinder head and check for flatness.
IMPORTANT: Avoid Damage! Oil port in gasket
(A) must be located over oil passage
in cylinder block.
3. Place a new cylinder head gasket on cylinder block

with locating pins on front and rear of block inside
holes in gasket. Line up oil port on right front of block
with oil port (A) in gasket.
4. Clean threads of cylinder head bolts and oil washers A—Oil Port
and threads before installing.
5. Install head bolts and tighten in sequence shown.

Tighten in three steps from specifications.
Cylinder Head Bolts—Specification
Initial Pass—Torque....................................................... 30 N·m (22 lb-ft)
Second Pass—Torque.................................................... 50 N·m (37 lb-ft)
Final Pass—Torque........................................................ 70 N·m (51 lb-ft)
6. Install camshafts. See Remove and Install Camshafts.

7. Install intake manifold. See Remove and Install Intake
Manifold.
8. Install exhaust manifold. See Exhaust Manifold
9. install timing belt sprocket and timing belt. See Timing
Belt Removal and Installation.
30-25-21
Repair
Remove and Install Intake Manifold

1. If engine is installed in vehicle, drain coolant into an
approved container.
2. Remove clip (A). Loosen jam nuts (B) and disconnect
throttle cable from throttle lever. Move cable aside.
3. Disconnect coolant hoses (C).
4. Disconnect intake air hose (D).
5. Disconnect intake air pressure/temperature sensor (E).
6. Disconnect idle air control (F) and throttle position
sensor (G).
7. Remove bolt (H) from coolant tube support bracket.
A—Clip E—Intake Air Pressure/Tem-

B—Jam Nut (2 Used) perature Sensor
C—Coolant Hose (2 Used) F— Idle Air Control Sensor
D—Intake Air Hose G—Throttle Position Sensor
H—Bolt
8. Remove seven intake manifold mounting nuts (I) and

remove intake manifold.
9. Remove gasket and clean mating surfaces. Check
flange for flatness with straightedge. Check manifold
for cracks or damage.
10. Install new gasket and install manifold in the reverse
order of removal.
11. Tighten all mounting cap screws to specification.
Specification
Intake Manifold Cap
Screw—Torque............................................................... 6 N·m (53 lb-in.)
I— Manifold Mounting Nuts (7

Used)
Exhaust Manifold Removal and Installation

Removal
1. If engine is in machine, make sure manifold is cool
enough to work on.
2. Remove the two bolts and nuts holding the exhaust
pipe on, and disconnect exhaust pipe.
3. Remove three bolts (A) and remove heat shield.
A—Heat Shield Retaining Bolts

(3 used)
30-25-22
Repair
4. Remove six nuts (B) and remove exhaust manifold.

Installation
1. Clean any old gasket material from cylinder head,
exhaust pipe, and exhaust manifold.
2. Install new gasket on cylinder head and install
manifold. Tighten nuts to specification.
Specification
Exhaust Manifold
to Cylinder Head
Nuts—Torque............................................................. 15 N·m (133 lb-in.)
3. Install new gasket on exhaust pipe. Install bolts and B—Nut (6 Used)
nuts and tighten to specification.
Specification
Exhaust Manifold
to Exhaust Pipe
Nuts—Torque................................................................. 73 N·m (54 lb-ft)
Recondition Cylinder Head

NOTE: Order tools according to information given in
Equipment
• Valve Spring Compressor

• Valve Stem Seal Protector
• Intake Valve Seal Installer
• Exhaust Valve Seal Installer
• Valve Shim Removal Tool
Disassembly and Assembly
1. Mark all valve adjusting shims (A) and valve lifters (B)
so that they can be installed in their original positions.
It works well to remove the oil film with a brake cleaning
product and then use a permanent marking pen. A—Valve Adjusting Shims B—Valve Lifters
2. Remove all valve adjusting shims and lifters.
30-25-23
Repair
3. Compress valve springs using Valve Spring

Compressor (C).
4. Remove collet halves (D) from valve with a small
magnet.
5. Slowly release compressor and valve spring.
C-Valve Spring Compressor D—Collet Halves
6. Remove sleeve (E) valve spring retainer (F), valve

spring (G), stem seal (H), and valve from head.
7. Inspect all parts for wear or damage. Clean all carbon
deposits and measure all parts for proper clearances.
8. Apply clean engine oil on intake and exhaust valve
stems during assembly.
E—Sleeve G—Valve Spring

F— Spring Retainer H—Stem Seal
IMPORTANT: Avoid Damage! DO NOT reuse stem

seals (H). Used seals will leak.
9. Install Valve Seal Protector (J) on valvestem.

Lubricate new valve oil seal (H) with cleanengine
oil and slide down on protector.
10. Use Valve Seal Installer (L) for intakevalves or
Valve Seal Installer for exhaustvalves and tap oil
seal into place.
H—Oil Seal L- Valve Seal Installer

J— Valve Stem Seal
Protector
30-25-24
Repair
NOTE: Use a small dab of grease on the inside of the

collets to make them stick to the valve stem.
11. Use valve spring compressor to compress spring (D)

and retainer. Install sleeve and collets (E).
Inspection and Replacement
Before inspection, thoroughly clean all components of
carbon or dirt.
D—Spring E—Collets
Cylinder Head
• Measure cylinder head flatness. Place a straightedge
along each of the four sides and each diagonal shown
with dark lines (A). Measure clearance between
straightedge and combustion surface with a feeler
gauge.
If distortion exceeds specifications, replace cylinder
head.
Specification
Cylinder Flatness
Distortion—Distance.................................................. 0.08 mm (0.003 in.)
• Measure valve seat width (C).

• If necessary, grind valve seats to meet specifications.
See Valve Seat Grinding in Recondition Cylinder Head.
C—Valve Seat Width
30-25-25
Repair
Intake and Exhaust Valves

• Check valve for out-of-round, bent, or warped condition
using a valve inspection center and dial indicator.
Replace valve if necessary.
• If valve faces are worn, burned, or pitted, grind valves

to proper face angle of 45°. If valve face margin (A) is
less than specification after grinding, replace valve.
Specification
Intake Valve Face
Margin—Thickness.................................0.8—1.2 mm (0.031—0.047 in.)
Exhaust Valve Face
Margin—Thickness.................................0.8—1.2 mm (0.031—0.047 in.)
Valve Face Margin Wear
Limit—Thickness....................................................... 0.75 mm (0.030 in.)
Intake Valve
A—Valve Face Margin
Face—Angle........................................................................................45°
Exhaust Valve
Face—Angle........................................................................................45°
• Measure valve stem diameter at the location shown (C)

down from end of valve. Replace valve if measurement
exceeds wear limit.
Specification
“C”—Distance............................................................... 35 mm (1.378 in.)
Intake Valve
Stem—Diameter.................................4.96—4.98 mm (0.195—0.196 in.)
Exhaust Valve
Stem—Diameter.................................4.95—4.97 mm (0.195—0.196 in.)
Valve Guide Measurement
• Clean valve guides using a valve guide brush.
• Measure valve guide inside diameter using a ball or
telescoping snap gauge.
• If valve guide inside diameter exceeds wear limit,
replace cylinder head.
• If valve guide inside diameter is less than wear limit, C—35 mm (1.378 in.)
determine guide-to-stem clearance (valve guide
diameter minus valve stem diameter).
Specification Intake Valve Guide-to-
Intake Valve Valve Stem—Clearance.................0.030—0.060 mm (0.001—0.002 in.)
Guide—Diameter..............................5.00—5.018 mm (0.197—0.198 in.) Exhaust Valve
Exhaust Valve Guide-to-Valve
Guide—Diameter..............................5.00—5.018 mm (0.197—0.198 in.) Stem—Clearance...........................0.030—0.068 mm (0.001—0.003 in.)
30-25-26
Repair
Valve Springs
• Measure spring free length.Replace spring if
measurement exceeds specification.
Specification
Valve Spring Free Length
(Nominal)—Height........................................................ 37 mm (1.457 in.)
• Measure spring inclination.

Replace spring if
measurement (A) exceeds specification.
Specification
Maximum Spring
Inclination—Distance................................................... 1.2 mm (0.047 in.)
A—Spring Inclination
Valve Seat Grinding

NOTE: LIGHTLY grind valve seats for only a few seconds
to avoid excessive valve seat width. If valve guide is
to be replaced, always replace guide before grinding
valve seat, as seat grinder pilot is centered by guide.
1. Grind intake and exhaust valve seats using a 45° seat

grinder. Follow tool manufacturer’s instructions.
2. Measure valve seat width (A) after grinding.
A—Valve Seat Width
30-25-27
Repair
3. If the seat (B) is too wide after grinding, grind lower

seat surface (C) using a 70° seat grinder until seat
width is close to specifications.
4. Grind upper seat surface (D) using a 30° seat grinder
until seat width is narrowed to specifications.
Specification
Intake Valve Seat
Width—Distance.................................................................................. NA
Exhaust Valve Seat
Width—Distance.................................................................................. NA
5. Dimension (E) is 45° for intake and exhaust seat.

6. If valve seats are ground, check contact pattern
between the seat and valve with bluing dye.
7. Lap valves. See Valve Lapping in Recondition
Cylinder Head.
B—Seat D—Upper Seat Surface

C—Lower Seat Surface E—45°
LVAL22530 —UN—01MAY12
Valve Lapping
1. Apply small amount of fine lapping compound to face
of valve.
2. Turn valve with valve lapping tool to lap valve to seat.
3. Lift valve from seat every 8 to 10 strokes. Lap until
a uniform ring appears around the surface (A) of the
valve face.
4. Wash all parts in solvent to remove lapping compound. A—Valve Seat Surface
Dry parts.
5. Check position of lap mark on valve face. Lap mark
must be at or near center of valve face.
Remove and Install Oil Pan

Removal
1. Remove oil pan cap screws (A).
IMPORTANT: Avoid Damage! Use care not to bend
oil pan when trying to break the seal.
2. Use a thin tool like a putty knife to break the bond of the
gasket sealant and carefully pry oil pan (B) from block.
A—Cap Screws B—Oil Pan
30-25-28
Repair
3. Remove cap screws for oil pickup tube (C) and remove
oil pickup tube (D).
Installation
1. Replace gasket on pickup tube, and install pickup tube.
2. Clean gasket mating surfaces and apply
Form-in-Place Gasket on all mating
surfaces.
3. Install oil pan. Tighten cap screws to specification.
Specification
Oil Pan Cap
Screw—Torque............................................................... 6 N·m (53 lb-in.)
Oil Pan—Capacity...............................................................2.2 L (2.3 qt.)
C—Screws (3 Used) D—Oil Pickup Tube
Remove and Install Oil Pump

Removal
1. Remove crankshaft pulley bolt (A) and crankshaft
pulley. Remove dipstick tube (B).
A—Crankshaft Pulley Bolt B—Dipstick Tube
30-25-29
Repair
2. Remove timing belt covers (C).
C—Upper and Lower Timing

Belt Covers
3. Remove alternator bolts (D) and alternator.

4. Remove belt guide (E).
IMPORTANT: Avoid Damage! Do not pry on timing
belt with sharp tools such as a screwdriver.
Belt will be damaged.
5. Remove timing belt idler (F) and timing belt (G).

6. Remove timing belt drive sprocket (H) from crankshaft.
7. If not already done, drain engine oil.
D—Alternator Bolts (2 Used) G—Timing Belt

E—Belt Guide H—Timing Belt Drive Sprocket
F— Timing Belt Idler
30-25-30
Repair
8. Remove oil pan and oil pickup tube (J). See Remove
and Install Oil Pan.
I— Bolt (3 Used) J— Oil Pick-up Tube
9. Remove six mounting cap screws (K) and remove oil

pump (L).
10. Inspect all parts for wear or damage. See
Disassembly, Inspection and Assembly in Remove
and Install Oil Pump.
K—Cap Screws (6 used) L— Oil Pump
30-25-31
Repair
CAUTION: Avoid Injury! Be careful when

releasing tension from relief valve spring.
Wear eye protection.
3. Bend cotter pin straight. Hold spring retainer (E) in with

screwdriver while removing cotter pin (F), then carefully
release spring tension and remove relief valve parts.
4. Clean all parts in an approved solvent.
E—Spring Retainer F— Cotter Pin
5. Inspect valve (G) for nicks or scratches. Inspect spring

(H) for wear or broken coils. Inspect spring retainer
(I) for damage. Inspect valve seat (J) for damage or
foreign particles. Replace any worn or damaged parts.
G—Relief Valve I— Spring Retainer

H—Spring J— Valve Seat
6. Inspect rotor bore and bottom (K) for any deep

scratches or wear. If worn/scratched replace entire
oil pump.
K—Rotor Bore
30-25-33
Repair
7. Inspect inside of rotor cover (L) for any deep scratches

or wear. If worn/scratched replace entire oil pump.
L— Rotor Cover
8. Check outer rotor-to-pump housing clearance (M). If

clearance is more than wear limit, replace oil pump.
Specification
Outer Rotor-to-Pump
Body—Clearance.............................0.10—0.181 mm (0.004—0.007 in.)
Outer Rotor-to-Pump
Body Wear
Limit—Clearance....................................................... 0.25 mm (0.010 in.)
M—Outer Rotor-to-Pump
Housing Clearance
9. Check inner-to-outer rotor clearance (N). If clearance

exceeds wear limit, replace oil pump.
Specification
Inner Rotor-to-Outer
Rotor—Clearance...............................0.05—0.18 mm (0.002—0.007 in.)
Inner Rotor-to-Outer
Rotor Wear
Limit—Clearance....................................................... 0.35 mm (0.014 in.)
N—Inner Rotor-to-Outer Rotor

Clearance
30-25-34
Repair
Assembly
1. Oil all parts with clean engine oil when assembling.
2. Install inner and outer rotors with marks (A) facing
toward you.
A—Alignment Marks
3. Install rotor cover (B).
B—Rotor Cover
4. Install relief valve (C), spring (D), and retainer (E).

5. Compress spring with screwdriver and install new
cotter pin.
C—Relief Valve E—Retainer

D—Spring
30-25-35
Repair
6. Replace front oil seal (F). The oil seal should be flush
with the bore.
F— Oil Seal
Remove and Install Crankshaft Front Oil Seal

NOTE: Front oil seal can be replaced with engine in the
machine. Some photos in this section are shown
with engine out for clarity of photo.

2. Remove timing belt covers, tensioner (A), and timing
belt (B). See Timing Belt Removal and Installation.
3. Remove belt guide (C).
4. Remove timing belt sprocket (D) from crankshaft.
There are threaded holes in the sprocket for a puller if
necessary.
A—Belt Tensioner C—Belt Guide

B—Timing Belt D—Timing Belt Sprocket
5. Carefully pry oil seal (E) from oil pump.
E—Oil Seal
30-25-36
Repair
6. Coat lip of new seal with clean engine oil and install
seal with lip toward engine. Install seal using seal tool
(F) as shown. Install seal flush with surface of cover.
F— Seal Installation Tool
7. Install timing gear sprocket with timing dot (G) to the

outside.
8. Install new timing belt and time crankshaft to camshaft.
See Timing Belt Removal and Installation, and
assemble front of engine.
9. Tighten fasteners to specifications.
Specification
Crankshaft Pulley Cap
Screw—Torque............................................................... 98 N•m (72 lb-ft)
Cap Screw—Torque....................................................... 25 N•m (18 lb-ft)
G—Timing Dot
30-25-37
Repair
Remove and Install Camshafts

Removal
1. Remove valve cover. See Remove and Install Valve
Cover.
2. Remove the upper (N) and lower (O) timing belt covers.
N—Upper Timing Belt Cover O—Lower Timing Belt Cover
3. Remove belt guide (P).
P—Belt Guide
30-25-38
Repair
IMPORTANT: Avoid Damage! Do not use a

screwdriver or any sharp edged tool to
pry belt off of sprockets.
4. Remove belt tensioner (F). Remove the timing belt.
F— Belt Tensioner
5. Remove camshaft sprocket bolt and washer (G) and

cam sprocket (H).
G—Camshaft Sprocket Bolt H—Camshaft Sprocket

and Washer
6. Set up a dial indicator and check end play on

exhaust camshaft (I) and intake camshaft (J). Record
measurements.
Specification
Intake Camshaft—End
Play......................................................0.1—0.17 mm (0.004—0.007 in.)
Exhaust Camshaft—End
Play....................................................0.1—0.173 mm (0.004—0.007 in.)
Camshaft End Play
(Max)—End Play....................................................... 0.18 mm (0.007 in.)
I— Exhaust Camshaft J— Intake Camshaft
30-25-39
Repair
7. Remove five bolts (K) and the front cam housing (L).
K—Bolts (5 Used) L— Front Cam Housing
8. Install a 5 mm x 80 bolt (M) into the hole next to the

pinned hole on the intake camshaft to hold master and
slave gears in position.
M—5 mm x 60 Bolt
9. Loosen camshaft bearing cap bolts in the sequence

shown.
30-25-40
Repair
NOTE: The cam bearing caps are numbered two, three,

and four and have an arrow pointing toward the
gear end of camshaft. Caps must be installed in the
same position and direction as when removed.
10. Remove the camshaft bearing caps (N).
N—Camshaft Bearing Caps
IMPORTANT: Avoid Damage! There is pressure

from the valve springs on the camshafts.
Keep camshafts parallel with the cylinder
head when removing and be prepared for a
sudden release of spring pressure.
11. Lift intake (O), and exhaust (P), camshafts out of

cylinder head.
12. Inspect all parts for wear or damage. See Camshaft
Inspection in Remove and Install Camshafts.
P—Intake Campshaft Q—Exhaust Camshaft
Installation
1. Install camshafts. Gear tooth with timing mark (A) on
intake camshaft must be between two marks (B) on
exhaust cam gear.
A—Intake Camshaft Timing B—Exhaust Camshaft Timing

Mark Mark
30-25-41
Repair
2. Bearing caps are numbered 2, 3, and 4 and have an

arrow that should point toward the front of the engine
(cam gear end). Bearing cap two is installed next to
the camshaft gears, then three etc.
3. Tighten bearing cap bolts to specification in sequence
shown.
Specification
Camshaft Bearing Cap
Screw—Torque..........................................................................9 ± 1 N·m
(80 ± 9 lb.-in.)
4. Remove bolt (C) from intake cam gears.

5. Apply a thin bead of Form-in-Place Gasket (D) on
cylinder head in areasshown.
C—Bolt D—Form-in-Place Gasket

Sealant
6. Install front camshaft housing and tighten bolts to

specification in order shown.
Specification
Front Camshaft Housing
Bolts—Torque...................................................................................... NA
7. Install valve cover. See Remove and Install Valve

Cover.
30-25-42
Repair
8. Place a few drops of Loctite 545® on threads of

camshaft sprocket bolt and install timing belt sprocket
on camshaft. Make sure camshaft drive pin (E) is
engaged in slot (F) in sprocket.
9. Tighten bolt to specification.
Specification
Camshaft Sprocket
Bolt—Torque........................................................................................ NA
10. Install timing belt and tensioner. See Timing Belt

Removal and Installation, and assemble front of
engine.
E—Camshaft Drive Pin F— Slot
Loctite is a trademark of Henkel Corporation
Camshaft Inspection
1. Inspect camshaft for bend by using a pair of V-blocks
(K) and a dial indicator. Turn camshaft slowly and read
variation of camshaft bearing journals (L) on indicator.
If variation is greater than wear limit, replace camshaft.
2. Inspect camshaft lobes. If there are chips or scratches
in lobes or bearing journals, replace camshaft.
K—V-Blocks (2 Used) L— Camshaft Bearing Journals
3. Measure camshaft front end journals (M) and

intermediate journal (O) outside diameters.
If journal diameters are less than wear limit, replace
camshaft.
Specification
Intake Cam Front
Journal—Diameter.................................................. 25.97 mm (1.022 in.)
Intake Cam 2, 3 & 4th
Journals—Diameter................................................. 22.97 mm (0.904 in.)
Exhaust Cam Front M—Front End Journal O—Intermediate Journals
Journal—Diameter.................................................. 29.967 mm (1.18 in.)
Exhaust Cam 2, 3 & 4th
Journals—Diameter............................................... 22.967 mm (0.904 in.)
30-25-43
Repair
Check Crankshaft Main Bearing Clearance

Reason
To measure oil clearance between main bearing and
crankshaft journal.
Procedure
IMPORTANT: Avoid Damage! Main bearing caps
must be installed on the same main bearing
and in the same direction to prevent crankshaft
and main bearing damage.
1. Remove main bearing cap.

2. Wipe oil from bearing insert and crankshaft journal.
3. Put a piece of Plastigage® (A), on the crankshaft A—Plastigage®
journal approximately 6 mm (0.250 in.) off center.
4. Install main bearing cap and cap screws. Tighten cap
screws to specification. DO NOT turn crankshaft. 5. Remove cap screws and main bearing cap.
Specification
Main Bearing Cap
Screw—Torque............................................................... 78 N·m (58 lb-ft)
NOTE: The flattened PLASTIGAGE will be found on

either the bearing insert or crankshaft journal.
6. Use the graduation marks on the envelope (B) to

compare the width of the flattened Plastigage® (C) at
its widest point.
7. Determine main bearing clearance. The number within
the graduation marks indicates the bearing clearance
in inches or millimeters, depending on which side of
the envelope is used.
8. Remove Plastigage®.
Results
If clearance exceeds specification, measure crankshaft
main bearing journals. See Inspection and Repair in B—Envelope C—Flattened Plastigage®
Remove and Install Crankshaft and Main Bearings. If
bearing journals are within specification, replace bearing
inserts. Crankshaft Main Bearing
Specification Wear Limit—Clearance............................................. 0.15 mm (0.006 in.)
Crankshaft Main
Bearing—Clearance...................0.020—0.072 mm (0.0008—0.0028 in.)
30-25-44
Repair
Check Connecting Rod Bearing Clearance

Reason
To measure oil clearance between connecting rod bearing
and crankshaft journal.
Procedure
IMPORTANT: Avoid Damage! Connecting rod caps
must be installed on the same connecting rod
and in the same direction to prevent crankshaft
and connecting rod damage.
1. Remove connecting rod cap.

2. Wipe oil from bearing insert and crankshaft journal. A—Plastigage®
3. Put a piece of Plastigage® (A), or an equivalent, on

the bearing journal approximately 6 mm (0.250 in.)
off center. Specification
Connecting Rod Cap
4. Install connecting rod end cap and original cap screws. Screw—Torque............................................................... 40 N·m (30 lb-ft)
Tighten cap screws to specification. DO NOT turn
crankshaft. 5. Remove cap screws and connecting rod cap.
NOTE: The flattened Plastigage® will be found on either

the bearing insert or crankshaft journal.
6. Use the graduation marks on the envelope to compare

the width of the flattened Plastigage® (B) at its widest
point.
7. Determine bearing clearance. The number within the
graduation marks indicates the bearing clearance in
inches or millimeters, depending on which side of the
envelope is used.
8. Remove Plastigage®.
Results
If clearance exceeds specification, replace bearing inserts.
Specification
Connecting Rod Bearing B—Envelope C—Flattened Plastigage
Oil—Clearance...............................0.020—0.044 mm (0.001—0.002 in.)
Wear Limit—Clearance............................................. 0.07 mm (0.003 in.)
30-25-45
Repair
Check Connecting Rod Side Play

Reason
To determine proper side clearance between the
crankshaft and the connecting rod.
Procedure
1. Remove the oil pan and oil pick-up assembly. See
Remove and Install Oil Pan.
2. Insert a feeler gauge blade (A) between the connecting
rod cap and the crankshaft. Increase blade thickness
until slight drag is felt when sliding feeler gauge
back and forth. Record reading and check with
specifications.
A—Feeler Gauge Blade
Results
If the side play exceeds specifications, replace the
Connecting Rod Side
connecting rod and/or crankshaft.
Play―Wear Limit—End
Specification Play........................................................................... 0.30 mm (0.012 in.)
Connecting Rod Side
Play—End Play..................................0.15—0.24 mm (0.006—0.009 in.)
Repair Piston and Connecting Rod

Removal
1. Remove oil pan and strainer tube. See Remove and
Install Oil Pan.
2. Remove cylinder head. See Remove and Install
Cylinder Head.
3. Check cylinder bore for ridges. A ridge can damage
piston and rings if ridge is not removed. If necessary,
remove ridge from top of cylinder bore using a ridge
reamer.
4. Measure connecting rod side play. See Check
Connecting Rod Side Play.
5. Measure connecting rod bearing clearance. See Note connecting rod matching numbers (A) in relation to
the cylinder number.
Check Connecting Rod Bearing Clearance.
IMPORTANT: Avoid Damage! Keep connecting rods A—Connecting Rod Numbers C—Connecting Rod Cap
and caps together. Rods and caps are a matched B—Nut (2 Used)
set. Note matching numbers (A) on each part.
Pistons and cylinders are matched. Pistons
must be installed in the cylinders from 8. Disassemble and inspect all parts for wear or damage.
which they are removed. See Inspection and Replacement in Repair Piston.
6. Remove two nuts (B) connecting rod cap (C).

7. Push piston and connecting rod out of cylinder bore
using a wooden dowel.
30-25-46
Repair
Installation
1. If new piston rings were installed, deglaze cylinder
bore. See Cylinder Bore.
2. Install piston rings so piston ring end gaps are
staggered 120° apart.
IMPORTANT: Avoid Damage! DO NOT touch bearing
insert surfaces. Oil and acid from your finger
will corrode the bearing surface.
3. Install bearing inserts on connecting rod and rod cap,

aligning tangs with grooves.
IMPORTANT: Avoid Damage! Pistons must be
installed in cylinders from which they were
removed and in the same direction. Be
careful not to damage crankshaft rod journal
while installing piston. A—Alignment Dimple
4. Coat cylinder, piston skirt, rod, and bearing surfaces

with oil. removed with the dimple on the piston (A) toward the
front of the engine.
5. Install ring compressor on piston and install piston
and connecting rod into the cylinder from which it was
IMPORTANT: Avoid Damage! Connecting rod caps

must be installed on the same connecting
rods they were removed from. Match
numbers on rod and cap.
6. Install the connecting rod caps with matching numbers

(B) on the same side.
7. Tighten nuts (C) to specification.
Specification
Connecting Rod
Nut—Torque................................................................... 40 N·m (30 lb-ft)
8. Install cylinder head. See Remove and Install Cylinder

Head.
9. Install oil pickup tube and oil pan. See Remove and
Install Oil Pan.
B—Matching Numbers C—Nuts (2 Used)
30-25-47
Repair
Repair Piston
Disassembly
installed on the same connecting rod they
were removed from.
• Mark each piston and connecting rod to aid in assembly.

• Inspect all parts for wear or damage. Replace as
necessary.
A—Top Compression Ring G—Connecting Rod Bolts

(Chrome) H—Connecting Rod
B—Second Compression Ring I— Bearing Inserts
(Black) J— Connecting Rod Cap
C—Oil Ring (2 Used) K—Nuts
D—Oil Ring Expander
E—Piston
F— Piston Pin
30-25-48
Repair
Assembly
installed on the same connecting rod they
were removed from.
NOTE: Apply clean engine oil to all parts during assembly.
1. Connecting rod and piston must be assembled with

front mark dot (A) on top of piston on the same side
as connecting rod front marks (B).
A—Front Mark Dot B—Connecting Rod Front

Marks
Note: Piston pin is a press fit into connecting rod.
2. Heat piston pin end of connecting rod to 300°C

(570°F) before pressing in piston pin.
3. Install piston onto connecting rod with “front” marks
(A and B) facing the same direction. Lubricate piston
pin and press into connecting rod leaving an equal
amount of piston pin on each side of connecting rod.
A—Front Mark Dot B—Connecting Rod Front

Marks
30-25-49
Repair
4. Install oil ring expander in bottom ring groove of piston

with end (C) above either end of piston pin (D).
5. Install oil ring over expander with ring gap (E) opposite
(180°) of expander ends.
C—Oil Ring Expander, Open E—Ring Gap

End
D—Piston Pin
6. Install second compression ring (black) with

manufacturer's mark (G) (near ring gap) toward top
of piston. Turn ring until gap (F) is 120° away from
oil ring gap.
7. Install first compression ring (chrome), with
manufacturer's mark (G) (near ring gap) toward top of
piston, in top groove. Turn ring until gap is 180° away
from second ring gap.
F— Ring Gap G—Manufacturer’s Mark
30-25-50
Repair
Inspection and Replacement

1. Inspect all parts for wear or damage. Replace as
necessary.
2. If not already done determine connecting rod bearing
clearance. See Check Connecting Rod Bearing
Clearance.
• If bearing clearance exceeds wear limit and
crankshaft is within specifications, replace bearing
inserts.
Connecting Rod Bearing Clearance—Specification
Connecting Rod
Bearing—Clearance.....................0.020—0.044 mm (0.0008—0.002 in.)
• If crankshaft journal OD does not meet minimum

specification, replace bearing inserts and crankshaft.
Piston Ring Groove Side Clearance—Specification
Specification
Top Piston
Crankshaft Connecting
Ring—Clearance................................0.03—0.06 mm (0.001—0.002 in.)
Rod Journal—Diameter.....................36.984—37 mm (1.456—1.457 in.)
Top Piston Ring
3. With rings installed on piston, measure piston ring (Max)—Clearance..................................................... 0.12 mm (0.005 in.)
groove clearance between piston and ring with feeler Second Piston
gauge. Measure several places around each groove. Ring—Clearance................................0.03—0.06 mm (0.001—0.002 in.)
Second Piston Ring
If clearance exceeds maximum limit, replace rings or (Max)—Clearance..................................................... 0.11 mm (0.004 in.)
piston.
30-25-51
Repair
4. Measure piston ring end gap (P). Push ring into

cylinder bore, using a piston, until ring is approximately
45 mm (1.77 in.) (Q) from top of cylinder bore.
If end gap exceeds wear limit, replace rings.
Piston Ring End Gap—Specification
Top Ring—Gap...................................0.25—0.40 mm (0.010—0.016 in.)
Top Ring Wear
Limit—Gap................................................................ 0.65 mm (0.026 in.)
Second Ring—Gap............................0.35—0.50 mm (0.014—0.020 in.)
Second Ring Wear
Limit—Gap................................................................ 0.65 mm (0.026 in.)
Oil Control Ring—Gap......................0.20—0.070 mm (0.008—0.028 in.)
Oil Control Ring Wear
Limit—Gap................................................................ 1.00 mm (0.075 in.)
P—Ring End Gap Q—45 mm (1.77 in.)
30-25-52
Repair
5. Measure piston pin diameter. Measure diameter at

each end 8 mm (0.31 in.) in from outside of pin (R).
R—Piston Pin (Outside

Diameter)
6. Measure diameter of piston pin bores in two directions

90° to each other and 8 mm (0.31 in.) in from outside
of piston.
If bore clearance (bore ID minus pin OD) exceeds
specification, replace piston, piston pin, or both.
Piston Pin Clearance—Specification
Piston Pin-to-
Bore—Clearance....................0.004—0.009 mm (0.00015—0.00035 in.)
Piston Pin-to-Bore Wear
Limit—Clearance................................................... 0.015 mm (0.0006 in.)
30-25-53
Repair
7. Measure piston diameter perpendicular to piston pin

11 mm (0.43 in.) up from bottom of skirt. If piston
diameter is less than wear limit, install a new piston.
Specification
Piston—Diameter................................................................................ NA
8. Measure cylinder bore diameter. See Cylinder Bore.
Cylinder Bore
Inspection
Measure cylinder bore diameter at three positions: top
(A), middle (B), and bottom (C). At these three positions,
measure in both directions: along crankshaft centerline
(E) and in direction of crankshaft rotation (D).
Cylinder Bore ID
If cylinder bore exceeds wear limit, replace cylinder block.
Specification
Cylinder Bore
(Max)—Diameter................................................... 72.085 mm (2.838 in.)
Piston-to-Cylinder
(Max)—Clearance..................................................... 0.10 mm (0.004 in.)
A—Top of Cylinder Bore D—Along Crankshaft

B—Middle of Cylinder Bore Centerline
C—Bottom of Cylinder Bore E—Direction of Crankshaft
Rotation
30-25-54
Repair
Deglazing
IMPORTANT: Avoid Damage! If cylinder bores are to
be deglazed with crankshaft installed in engine,
put clean shop towels over crankshaft to protect
journal and bearing surfaces from any abrasives.
1. Deglaze cylinder bores using a flex-hone with 180

grit stones.
2. Use flex-hone as instructed by manufacturer to obtain
a 30—40° crosshatch pattern as shown.
IMPORTANT: Avoid Damage! DO NOT use gasoline,
kerosene, or commercial solvents to clean
cylinder bores. Solvents will not remove all
abrasives from cylinder walls.
white rags and warm soapy water. Continue to clean
3. Remove excess abrasive residue from cylinder walls cylinder until white rags show no discoloration.
using a clean dry rag. Clean cylinder walls using clean
Remove and Install Crankshaft and Main

Bearings
Removal
1. Remove engine. See Remove and Install Engine.
2. Drain oil and remove oil pan. See Remove and Install
Oil Pan.
3. Remove oil pump. See Remove and Install Oil Pump.
4. Install dial indicator (A) on either end of engine
crankshaft. Pry crankshaft back and forth with a
screwdriver or similar tool and check crankshaft end
play.
5. Remove rear oil seal case. See Remove and Install
Crankshaft Rear Oil Seal.
6. Remove timing belt cover and timing belt. See Timing A—Dial Indicator
Belt Removal and Installation.
7. Check crankshaft bearing clearance. See Check
Crankshaft Main Bearing Clearance.
30-25-55
Repair
IMPORTANT: Avoid Damage! Connecting rod end

caps must be installed on the same connecting
rods from which they were removed. Note
numbers on caps and rods.
8. Remove connecting rod cap nuts and rod caps. Note

numbers (A) on rod and cap.
9. Push pistons and connecting rods away from
crankshaft.
A—Connecting Rod Matching

Numbers
NOTE: Main bearing caps are numbered 1 thru 4 and

have arrows cast on the cap. Both correspond to
their location on the engine block. Number one
cap is at the front of the engine and number four
is at the flywheel end. The caps are installed with
the arrows toward the front of the engine.
10. Remove eight main bearing cap screws (A) and

bearing caps (B).
A—Main Bearing Cap Screws B—Main Bearing Caps

(8 Used)
11. Remove the two thrust bearings (C) from number

three main bearing in engine block.
C—Crankshaft Thrust Bearings
30-25-56
Repair
12. Carefully lift out crankshaft (D).

13. Inspect all parts for wear or damage. See Inspection
and Repair in Remove and Install Crankshaft and
Main Bearings.
D—Crankshaft
Installation
IMPORTANT: Avoid Damage! DO NOT touch bearing
insert surfaces. Oil and acid from your finger
will corrode the bearing surface.
NOTE: Apply clean engine oil on all parts during

installation.
1. Install four upper bearing inserts with oil holes in

bearing (A) aligned with oil holes in cylinder block.
Align tangs on bearing (B) with slots in engine block.
2. Install crankshaft.
A—Oil Hole B—Bearing
3. Lubricate thrust bearing inserts (C). Install thrust

bearings into engine block with oil grooves facing
toward crankshaft.
C—Crankshaft Thrust Bearing
30-25-57
Repair
4. Tabs on thrust bearing (D) must be in longer cutout in

engine block and be flush with block.
D—Thrust Bearing Insert
5. Install smooth bearing inserts in main bearing caps,

aligning tangs (E) with slots in caps.
E—Tang
NOTE: Main bearing caps are numbered 1 thru 4 and

have arrows cast on the cap. Numbers correspond
to their location on the engine block. Number one
cap is at the front of the engine and number four is
at the flywheel end. The caps are installed with the
arrows toward the front of the engine. Number three
has the thrust bearing inserts in the engine block.
6. Install main bearing caps in their original locations (1-4

front to back) with arrows toward front of engine.
IMPORTANT: Avoid Damage! DO NOT use high-speed
power tools or air wrenches to tighten
main bearing cap screws.
7. Dip entire main bearing cap screws in clean engine oil.

Install cap screws.
30-25-58
Repair
8. Tighten main bearing cap screws in sequence shown

in three steps to specifications. Turn crankshaft by
hand after each cap is tightened. If it does not turn
easily, disassemble the parts and find the cause.
Main Bearing Cap Screws—Specification
First Pass—Torque......................................................... 24 N·m (18 lb-ft)
Second Pass—Torque.................................................... 48 N·m (36 lb-ft)
Final Pass—Torque..................................................... 70.5 N·m (52 lb-ft)
Inspection and Repair

1. Inspect crankshaft for bend using V-blocks (F) and
a dial indicator (G). Turn crankshaft slowly and read
variation on indicator. If variation is greater than
specification, replace crankshaft.
Specification
Crankshaft—Radial
Runout....................................................................... 0.03 mm (0.001 in.)
F— V-Block (2 used) G—Dial Indicator
30-25-59
Repair
2. Measure crankshaft connecting rod journals (G) and

main bearing journal (H) diameters. Measure several
places around each journal.
If journal diameter is less than wear limit, replace
crankshaft.
Specification
Crankshaft Connecting
Rod Journal—Diameter.....................36.984—37 mm (1.456—1.457 in.)
Crankshaft Main Bearing
Journal—Diameter............................41.984—42 mm (1.653—1.654 in.)
Crankshaft Main
Bearing—Clearance.......................0.025—0.069 mm (0.001—0.003 in.)
Crankshaft Main Bearing G—Connecting Rod Journals H—Main Bearing Journals
3. Clean and inspect oil passages in main bearing

journals, connecting rod journals, and main bearing 4. Inspect crankshaft for cracks or damage. Replace if
bores in cylinder block. necessary.
Remove and Install Crankshaft Rear Oil Seal

1. Remove outer belt cover.
2. Remove belt and both clutches.
3. Remove inner belt cover.
4. Remove the four bolts and the clutch stub shaft (A)
from flywheel.
A—Clutch Stub Shaft
IMPORTANT: Avoid Damage! FLYWHEEL IS HEAVY!

Do not remove flywheel mounting cap screws
unless flywheel is secure. Use a hoist and lift
rings to lift flywheel from crankshaft.
5. Remove two bolts (B) and remove flywheel speed

sensor.
6. Remove six flywheel mounting cap screws (C) and
remove flywheel from crankshaft.
B—Bolts (2 used) C—Flywheel Mounting Cap

Screws (6 Used)
30-25-60
Repair
NOTE: It is not necessary to remove oil seal case

to remove oil seal.
7. Use an oil seal removal tool and remove oil seal (C)
from oil seal case (D).
8. Replace oil seal using a driver set. Install seal with lip
toward cylinder block. Install seal flush with surface
of oil seal case.
C—Oil Seal D—Oil Seal Case
Remove and Install Rear Oil Seal Case

NOTE: It is not necessary to remove oil seal case to
remove oil seal. Oil seal case has to be removed
when crankshaft is removed from engine block.
1. Remove oil seal case-to-cylinder block cap screws (A).

2. Carefully pry oil seal case from engine block.
3. Remove oil seal from case.
4. Clean all old sealant from oil seal case and engine
block.
5. Apply a 3—4 mm bead of Form-in-Place
Gasket Sealer on matingsurface of engine block.
Install oil seal case andtighten cap screws to
specification.
Specification
Oil Seal Case Cap A—Cap Screw (5 Used)
Screws—Torque......................................................... 25 N·m (221 lb-in.)
6. Install new oil seal after oil seal case is installed.

Specification
7. Install flywheel onto crankshaft, aligning crankshaft Flywheel Mounting Cap
pin into flywheel mounting flange. Tighten cap screws Screw—Torque............................................................ 83.4 N·m (62 lb-ft)
to specification.
30-25-61
Repair
Alternator Removal and Installation

2. Disconnect negative (-) battery cable from battery.
3. Drain oil from transaxle. See Changing Transmission
Oil.
5. Loosen alternator bolts (C). Slide alternator toward

engine to loosen and remove belt (D).
6. Remove cap screw (E) and slide coupling (F) off of
transmission output shaft.
7. Remove cap screws (G) and move driveshaft aside.
C—Alternator Bolts (2 Used) F— Coupling

D—Belt G—Cap Screws (2 Used)
E—Cap Screw
NOTE: When removing FWD gearbox from transmission

tip the opening up to avoid losing the oil
from inside the case.
8. Remove cap screws (H) securing 90° FWD gearbox

to transmission.
9. Remove FWD gearbox from transmission. Hang the
gearbox from the machine frame with the open side
up to avoid losing the oil from it. Cover open end of
case with a clean rag.
10. If not already done, remove alternator mounting bolts.
H—Cap Screws (5 Used)
30-25-62
Repair
11. Press in on clip (J) on two wire plug and disconnect

plug.
12. Slide boot aside and remove nut (I) and wire from
alternator terminal.
13. Maneuver alternator out between engine and
transmission.
I— Nut J— Clip
Installation
1. Place alternator in position but do not install the
mounting cap screws.
2. Attach large wire and nut, and plug in the two wire
connector. Tighten nut on large wire and position boot
over terminal.
3. Install the alternator cap screws finger tight.
IMPORTANT: Avoid Damage! Do not overtighten
alternator belt. Overtightening the belt may
cause alternator to contact transmission case.
4. Install alternator belt and adjust belt tension. Tighten

cap screws.
5. Clean old sealant from FWD gearbox and transmission
flanges.
6. Apply a bead of Form-in-Place Gasket (A) to A—Form-in-Place Sealant B—Splined Coupling
transmission flange.
7. Install the splined coupling (B) on the transmission
output shaft.
8. Install the FWD gearbox and tighten cap screws.
30-25-63
Repair
5. Loosen hose clamp (D) and disconnect hose from

coolant tube (E).
6. Remove cap screws (F) securing coolant tube to
intake manifold.
7. Pull grommet (G) and throttle cable out of bracket.
8. Move coolant tube away from intake manifold and
secure it out of the way. Use care not to kink throttle
cable.
D—Hose Clamp F— Cap Screws (2 Used)

E—Coolant Tube G—Grommet
30-25-64
Repair
10. Slide boot (I) aside. Remove nut and disconnect

positive cable from starter solenoid.
11. Remove nut (J) and disconnect exciter wire from
solenoid.
I— Boot J— Nut
12. Pull starter (K) away from backplate and let the nose
cone drop down. Lift starter up motor end first, with
solenoid toward engine, and maneuver out between
intake manifold and transmission as shown.
K—Starter Motor
30-25-65
Installation
1. Maneuver starter (K) between intake manifold and
transmission, positioned as shown. Lower starter
down next to engine block and insert nose cone into
starter opening.
K—Starter Motor
2. Install exciter wire (J) and positive cable (I) onto starter
solenoid and tighten nuts. Slide protective boot over
positive cable end.
I— Positive Cable J— Exciter Wire
30-25-66
Repair
4. Place coolant tube (E) back into position and install

cap screws (F).
5. Connect coolant hose and tighten clamp (D).
6. Return throttle cable and grommet (G) into bracket.
7. Fill cooling system with coolant. See Fill and Bleed
Coolant System.
D—Clamp F— Cap Screw (2 Used)

E—Coolant Tube G—Grommet
Fuel Injector Replacement

2. Disconnect negative battery terminal.
CAUTION: Avoid Injury! Gasoline is extremely

flammable. DO NOT SMOKE. Always work in
a well-ventilated area away from open flame
or spark-producing equipment, including
equipment that utilizes pilot lights.
3. Allow engine to cool down before opening fuel system.

4. Place a rag under fuel manifold to catch fuel and
disconnect fuel line (A) from fuel manifold.
5. Clean area around fuel injectors. A—Fuel Line B—Cap Screws (2 Used)
6. Remove cap screws (B) and pull manifold away from
cylinder head. The fuel injectors will stay with the
manifold.
7. To remove fuel injector(s) from manifold, remove

clip(s) (B) and pull injector out of manifold.
B—Clips
30-25-67
Repair
Installation
1. Lubricate o-rings (C) before installation.
2. Install injector(s) in fuel manifold and install retaining
clip(s) (B).
3. Clean fuel injector holes in cylinder head.
4. Lubricate o-rings.
5. Install injectors/manifold assembly to cylinder head.
Secure with two cap screws.
6. Connect fuel line.
7. Connect negative battery terminal. B—Retaining Clips C—O-Rings
Exhaust Gas Oxygen Sensor Replacement

1. Park machine safely and allow engine to cool.
2. Disconnect oxygen sensor wire (about ten inches from
sensor).
3. Use socket or equivalent to remove sensor (A) from
exhaust manifold.
Installation
Install new sensor and connect wiring.
A—Exhaust Gas Oxygen

Sensor
Knock Sensor Replacement

2. Disconnect negative battery terminal.
3. Locate knock sensor (A) (under intake manifold and
above starter).
4. Disconnect wire connector (B).
5. Remove cap screw (C) and knock sensor.
Installation
1. Install knock sensor and tighten cap screw.
2. Connect sensor wire.
3. Connect negative battery terminal.
A—Knock Sensor C—Cap Screw
B—Wire Connector
30-25-68
Repair
Camshaft Position Sensor Replacement

2. Locate camshaft position sensor (A) on right rear
corner of cylinder head (viewing from flywheel end of
engine)
3. Disconnect plug (B).
4. Remove cap screw (C) and pull sensor out of cylinder
head.
Installation
1. Check and lubricate o-ring on cam sensor.
2. Install sensor and tighten cap screw.
3. Connect wiring.
A—Camshaft Position Sensor C—Cap Screw
B—Plug
Crankshaft Position Sensor Replacement

2. Crankshaft position sensor boot (A) is located at about
the ten o’clock position in the flywheel/clutch cover.
A—Crankshaft Position Sensor

Boot
3. Pull up boot and disconnect plug (B).

4. Remove cap screw (C) and sensor (D).
Installation
1. Install sensor and tighten cap screw.
2. Connect wiring and install boot into flywheel cover.
B—Plug D—Sensor
C—Cap Screw
30-25-69
Repair
Intake Manifold Pressure/Temperature

Sensor Replacement
2. Press tab (A) and disconnect plug from sensor.
3. Remove cap screw (B).
4. Pull manifold temperature/pressure sensor (C) out of
manifold.
A—Tab C—Manifold Temperture/Pres-

B—Cap Screw sure Sensor
Throttle Body Replacement

2. Drain two liters (2.1 qt.) of coolant from cooling system.
3. Loosen clamp (A) and disconnect intake air hose (B)
from throttle body.
4. Disconnect throttle cable (C) from throttle lever.
A—Clamp C—Throttle Cable

B—Intake Air Hose
30-25-70
Repair
5. Disconnect idle air control (D), throttle position sensor

(E), and coolant hoses (F).
6. Remove four cap screws (G) and remove throttle body.
Installation
1. If replacing throttle body, throttle lever must be
transferred from the old throttle body to the new one.
When removing throttle lever make note of throttle
return spring tension and install lever and springs with
the same amount of tension on the new throttle body.
2. Clean all old gasket material from throttle body and
intake manifold mating surfaces.
3. Install a new gasket and install throttle body with four
cap screws.
4. Connect the throttle position sensor, idle air control,
and throttle cable. D—Idle Air Control F— Coolant Hoses
E—Throttle Position Sensor G—Cap Screws (4 Used)
5. Install coolant hoses and tighten clamps.
6. Fill cooling system.
30-25-71
Section 40
Electrical
Contents
Page
Page
Operation and Diagnostics ............................ 40-05-1 Main Wiring Harness Color Codes
Diagnostic Information................................... 40-05-1 (SN 060001-) ........................................... 40-22-20
Wire Color Abbreviation Chart....................... 40-05-1 Engine Wiring Harness (SN
Reading Electrical Schematics ...................... 40-05-2 060001-) .................................................. 40-22-22
Common Circuit Tests ................................... 40-05-3 Engine Wiring Harness Color
Conductors for 12 Volt Circuits ...................... 40-05-3 Codes (SN 060001-)................................ 40-22-24
Group 10—Specifications Group 25—Operation and Diagnostics (SN -060000)

Specifications ................................................ 40-10-1 Power Circuit Operation (SN
service OBD2 OBD2 Equipment and Tools........................ 40-10-1 -060000) .................................................... 40-25-1
Other Material................................................ 40-10-3 Power Circuit Diagnosis (SN
-060000)....................................................40-25-1
Group 15—Component Location Unswitched Power.........................................40-25-1
Summary of References................................ 40-15-1 Switched Power.............................................40-25-6
Main Wiring Harness Cranking Circuit Operation (SN
Components .............................................. 40-15-1 -060000) .................................................. 40-25-12
ECU Pin Locations ........................................ 40-15-2 Cranking Circuit Electrical
ECM Pin Locations (SN -060000).................. 40-15-4 Schematic (SN -060000) ......................... 40-25-13
ECM Pin Locations (SN 060001-).................. 40-15-5 Cranking Circuit Diagnosis (SN
Load Center (SN 060001-) ............................ 40-15-6 -060000)..................................................40-25-14
Load Center Components (SN Procedure: ...................................................40-25-14
060001-) .................................................... 40-15-7 Charging Circuit Operation (SN
-060000) .................................................. 40-25-15
Group 20—Schematics and Harnesses (SN -060000) Charging Circuit Electrical
Main Schematic and Wiring Schematic (SN -060000) ......................... 40-25-16
Harness Legend (SN -060000).................. 40-20-1 Charging Circuit Diagnosis (SN
Main Electrical Schematic (SN -060000)..................................................40-25-18
-060000) .................................................... 40-20-3 Alternator Circuit..........................................40-25-18
Ground Circuits (SN -060000) ..................... 40-20-10 Hour Meter Circuit Operation (SN
Main Wiring Harness (SN -060000) .................................................. 40-25-20
-060000) .................................................. 40-20-11 Speedometer Circuit Operation
Main Wiring Harness Color Codes (SN -060000) ........................................... 40-25-20
(SN -060000) ........................................... 40-20-16 Tachometer Circuit Operation (SN
Engine Wiring Harness (SN -060000) .................................................. 40-25-21
-060000) .................................................. 40-20-18
Engine Wiring Harness Color
Codes (SN -060000)................................ 40-20-20
Group 22—Schematics and Harnesses (SN 060001-)

Summary of References................................ 40-22-1
EPAS Pin Locations (SN
060001-) .................................................... 40-22-1
Display Panel Pin Locations (SN
060001-) .................................................... 40-22-2
Main Schematic and Wiring
Harness Legend (SN 060001-).................. 40-22-3
Main Electrical Schematic (SN
060001-) .................................................... 40-22-5
Ground Circuits (SN 060001-) ..................... 40-22-13
Main Wiring Harness (SN
060001-) .................................................. 40-22-14
40-1
Contents
Page Page
Idle Air Control Motor (IAC) Circuit

Operation................................................... 40-30-3
Ignition Coil Operation ................................... 40-30-3
Fuel Injector Operation .................................. 40-30-3
Fuel Pump Operation .................................... 40-30-3
Malfunction Indicator Light (MIL)
Operation................................................... 40-30-4
Diagnostic Interface Circuit
Operation................................................... 40-30-4
Electronic Control Module/Relay
Module (ECM) Operation........................... 40-30-5
(SN -060000) ........................................... 40-25-35 ECU and General Sensor Circuit
Cooling Circuit Operation (SN Operation................................................... 40-30-5
ECU Sensor and Diagnostic Circuit
Diagnosis................................................... 40-30-6
Fuel Injection Circuit Electrical
Schematic (SN -060000) ........................... 40-30-7
Fuel Injection Circuit Electrical
Schematic (SN 060001-) ......................... 40-30-12
(EMFWD) (SN -060000) .......................... 40-25-41
4WD Circuit Electrical Schematic Group 35—Operation and Diagnostics - DTCs
(SN -060000) ........................................... 40-25-42 Error Codes List............................................. 40-35-1
4WD Electrical Circuit Diagnostics (SN Error Codes Description ................................ 40-35-2
-060000)..................................................40-25-44 P0031 — O2 Sensor Heater Circuit
4WD “ON” Input Circuits:.............................40-25-44 Low (Bank 1 Sensor 1)..............................40-35-3
4WD Mechanical Activation Procedure: .....................................................40-35-3
Circuit: .....................................................40-25-44 P0032 — O2 Sensor Heater Circuit
Light Circuit Operation (SN High (Bank 1 Sensor 1).............................40-35-4
-060000) .................................................. 40-25-46 Procedure: .....................................................40-35-4
Headlight Circuit Diagnosis (SN P0107 — Manifold Absolute Pressure
-060000)..................................................40-25-46 Circuit Low ................................................40-35-5
Headlight Circuit ..........................................40-25-46 Procedure: .....................................................40-35-5
Marker Lights Circuit (3-position P0108 — Manifold Absolute Pressure
switch) .....................................................40-25-48 Circuit High................................................40-35-5
Electronic Controller Power Flow Procedure: .....................................................40-35-6
Operation (SN -060000) .......................... 40-25-50 P0112 — Intake Air Temperature
Electronic Controller Power Circuit Low Input .......................................40-35-6
Flow Circuit Schematic (SN Procedure: .....................................................40-35-6
-060000) .................................................. 40-25-51 P0113 — Intake Air Temperature
Electronic Control Module (ECM) Circuit High Input.......................................40-35-7
Power Diagram (SN -060000) ................. 40-25-55 Procedure: .....................................................40-35-7
Troubleshooting Electronic P0116 — Engine Coolant Temperature
Controllers (SN -060000)......................... 40-25-56 Circuit Range/Performance
On Board Diagnostics (SN Problem.....................................................40-35-8
-060000) .................................................. 40-25-56 Procedure: .....................................................40-35-8
P0117 — Engine Coolant Temperature
Group 30—Operation and Diagnostics - Fuel Injection Circuit Low Input .......................................40-35-9
Summary of References................................ 40-30-1 Procedure: .....................................................40-35-9
Temperature/Mass Air Pressure P0118 — Engine Coolant Temperature
(TMAP) Sensor Circuit Circuit High Input.....................................40-35-10
Operation................................................... 40-30-1 Procedure: ...................................................40-35-10
Throttle Position Sensor (TPS)...................... 40-30-1 P0119 — Engine Coolant Temperature
Coolant Temperature Sensor Circuit Intermittent ...................................40-35-11
Circuit Operation........................................ 40-30-2 Procedure: ...................................................40-35-11
Knock Sensor Circuit Operation .................... 40-30-2 P0122 — Throttle/Pedal Position
Oxygen Sensor (O2) Circuit Circuit Input Low .....................................40-35-12
Operation................................................... 40-30-2 Procedure: ...................................................40-35-12
40-2
Contents
Page Page
P0123 — Throttle/Pedal Position P0506 — Idle Air Control System -

Circuit Input High.....................................40-35-13 RPM Lower Than Expected ....................40-35-29
Procedure: ...................................................40-35-13 Procedure: ...................................................40-35-29
P0130 — O2 Sensor Circuit P0507 — Idle Air Control System -
Malfunction (Bank 1 Sensor 1)................40-35-14 RPM Higher Than Expected ...................40-35-30
P0131 — O2 Sensor Circuit Low P0560 — System Voltage
Voltage (Bank 1 Sensor 1) ......................40-35-15 Problem...................................................40-35-31
P0132 — O2 Sensor Circuit High P0605 — Internal Control Module Read
Voltage (Bank 1 Sensor 1) ......................40-35-15 Only Memory (ROM) Error ......................40-35-32
P0134 — O2 Sensor No Activity P0650 — Malfunction Indicator Lamp
Detected (Bank 1 Sensor 1)....................40-35-16 (MIL) Control Circuit ................................40-35-33
P0230 — Fuel Pump Circuit MIL Not Illuminated When It Should
Malfunction..............................................40-35-17 Be:...........................................................40-35-34
Procedure: ...................................................40-35-17 MIL Illuminated When It Should Not
P0261 - Cylinder 1 — Injector Circuit Be:...........................................................40-35-34
Low..........................................................40-35-18 P1166 — O2 Sensor - Controller
Procedure: ...................................................40-35-18 Adaptation Diagnosis
P0262 — Cylinder 1 - Injector Circuit Malfunction..............................................40-35-34
High.........................................................40-35-18 Procedure: ...................................................40-35-35
Procedure: ...................................................40-35-19 P1624 — Cooling Fan Relay - Circuit
P0264 — Cylinder 2 - Injector Circuit Malfunction - “Low” Circuit ......................40-35-35
Low..........................................................40-35-19 Procedure: ...................................................40-35-35
Procedure: ...................................................40-35-19 P1625 — Cooling Fan Relay - Circuit
P0265 — Cylinder 2 - Injector Circuit Malfunction - “High” Circuit......................40-35-36
High.........................................................40-35-20 Procedure: ...................................................40-35-36
Procedure: ...................................................40-35-20
P0267 — Cylinder 3 - Injector Circuit Group 40—Operation and Diagnostics (SN 060001-)
Low..........................................................40-35-21 Summary of References................................ 40-40-1
Procedure: ...................................................40-35-21 Power Circuit Operation (SN
P0268 — Cylinder 3 - Injector Circuit 060001-) .................................................... 40-40-2
High.........................................................40-35-21 Power Circuit Diagnosis (SN
Procedure: ...................................................40-35-22 060001-)....................................................40-40-2
P0325 — Knock Sensor 1 Circuit Unswitched Power (Main)..............................40-40-2
Malfunction..............................................40-35-22 Unswitched Power (Aux) ...............................40-40-5
Procedure: ...................................................40-35-22 Switched Power.............................................40-40-5
P0335 — Crankshaft Position Sensor Cranking Circuit Operation (SN
Malfunction..............................................40-35-23 060001-) .................................................... 40-40-8
Procedure: ...................................................40-35-23 Cranking Circuit Diagnosis (SN
P0340 — Camshaft Position Sensor 060001-)....................................................40-40-9
Malfunction..............................................40-35-24 Cranking Circuit Diagnosis (SN
Procedure: ...................................................40-35-24 060001-)....................................................40-40-9
P0351 — Ignition Coil ‘A’ Primary Charging Circuit Operation (SN
Secondary Circuit Malfunction ................40-35-25 060001-) .................................................. 40-40-10
Procedure: ...................................................40-35-25 Charging Circuit Diagnosis (SN
P0352 — Ignition Coil ‘B’ Primary 060001-)..................................................40-40-11
Secondary Circuit Malfunction ................40-35-26 Charging Circuit Diagnosis (SN
Procedure: ...................................................40-35-26 060001-)..................................................40-40-11
P0353 — Ignition Coil ‘C’ Primary Hour Meter Circuit Operation (SN
Secondary Circuit Malfunction ................40-35-27 060001-) .................................................. 40-40-13
Procedure: ...................................................40-35-27 Speedometer Circuit Operation
P0505 — Idle Speed Actuator (SN 060001-) ........................................... 40-40-15
Command Signal Incorrect......................40-35-28 Tachometer Circuit Operation (SN
Procedure: ...................................................40-35-28 060001-) .................................................. 40-40-17
40-3
Contents
Page Page
Display Panel Operation (SN

060001-) .................................................... 40-45-5
Display Panel Replacement
Programming (SN 060001-) ...................... 40-45-5
Display Panel Tire Size
Programming (SN 060001-) ...................... 40-45-6
Overtemp Input (SN 060001-) ....................... 40-45-6
Oil Pressure Input (SN 060001-) ................... 40-45-6
Coolant Temperature Gauge (SN
060001-) .................................................... 40-45-6
Fuel Level (SN 060001-) ............................... 40-45-7
Tachometer (SN 060001-) ............................. 40-45-7
Speedometer (SN 060001-) .......................... 40-45-8
Electric Power Assist Steering
(EPAS) Operation (SN
060001-) .................................................... 40-45-9
Neutral Switch .............................................40-40-25 EPAM Test (SN 060001-) ............................ 40-45-10
Throttle Switch.............................................40-40-25 Live Readings (SN 060001-) ....................... 40-45-10
Oil Pressure Light Circuit Operation Approved Software for Control
Units (SN 060001-).................................. 40-45-11
(SN 060001-) ........................................... 40-40-27 Erroneous Diagnostic Trouble
Cooling Circuit Operation (SN Codes (SN 060001-)................................ 40-45-11
060001-) .................................................. 40-40-28
Cooling Circuit Electrical Diagnosis Group 60—Tests and Adjustments
(SN 060001-) ........................................... 40-40-31 Summary of References................................ 40-60-1
4WD Drive Circuit Operation Ground Circuit Test........................................ 40-60-2
(EMFWD) (SN 060001-) .......................... 40-40-32 Battery Test.................................................... 40-60-3
4WD Drive Circuit Diagnosis (EMFWD) Charge Battery .............................................. 40-60-4
(SN 060001-)...........................................40-40-34 Battery Load Test........................................... 40-60-5
4WD “ON” Input Circuits:.............................40-40-34 Clean Battery................................................. 40-60-5
4WD Mechanical Activation Regulated Voltage Output Test...................... 40-60-6
Circuit: .....................................................40-40-34 Starter Solenoid Test ..................................... 40-60-6
Light Circuit Operation (SN Starter Loaded Amperage Draw
060001-) .................................................. 40-40-36 Test ............................................................ 40-60-7
Light Circuit Diagnosis (SN Starter No-Load Amperage and
060001-)..................................................40-40-38 RPM Test ................................................... 40-60-8
Light Circuit Diagnosis (SN Key Switch Test ............................................. 40-60-9
060001-)..................................................40-40-38 Park Brake Switch Test.................................. 40-60-9
Test Procedure B: ........................................40-40-38 Reverse Switch Test .................................... 40-60-10
Electronic Controller Power Flow Headlight Switch Test (Single)..................... 40-60-11
Operation (SN 060001-) .......................... 40-40-40 Light Switch Test (3-position)....................... 40-60-11
4WD Switch Test ......................................... 40-60-12
Group 45—Operation and Diagnostics - Throttle Switch Test ..................................... 40-60-12
Electronic Controllers (SN 060001-) Brake Lights Switch Test ............................. 40-60-13
Summary of References................................ 40-45-1 Cargo Box Raise/Lower Switch
Troubleshooting Electronic
Controllers (SN 060001-)........................... 40-45-1 Test .......................................................... 40-60-13
On Board Diagnostics - ECU (SN Engine Coolant Temperature
060001-) .................................................... 40-45-2 Sensor Test.............................................. 40-60-14
On Board Diagnostics - Relay Engine Oil Pressure Switch Test ................. 40-60-15
Module (SN 060001-) ................................ 40-45-3 Seat Belt Switch Test................................... 40-60-15
Electronic Control Module/Relay Fuse Test ..................................................... 40-60-16
Module (ECM) Operation (SN Bulb Test...................................................... 40-60-16
060001-) .................................................... 40-45-4 Diode Test.................................................... 40-60-17
ECU and General Sensor Circuit Relay Test.................................................... 40-60-17
Operation (SN 060001-) ............................ 40-45-4 Speed Sensor Test ...................................... 40-60-18
ECU Sensor and Diagnostic Circuit 4WD Solenoid Test ...................................... 40-60-19
Diagnosis (SN 060001-) ............................ 40-45-5 Warning Alarm Test ..................................... 40-60-19
40-4
Contents
Page
Idle Air Control Test ..................................... 40-60-20

Ignition Coil Test .......................................... 40-60-21
Fuel Injector Test ......................................... 40-60-21
Knock Sensor Test....................................... 40-60-22
Fuel Pump Relay Command Test
(SN 060001-) ........................................... 40-60-22
Cooling Fan Relay High Command
Test (SN 060001-) ................................... 40-60-22
Cooling Fan Relay Low Command
Test (SN 060001-) ................................... 40-60-22
Main Relay Command Test (SN
060001-) .................................................. 40-60-23
Cylinder Shut-off Command Test
(SN 060001-) ........................................... 40-60-23
Ignition Coil 1 Command Test (SN
060001-) .................................................. 40-60-23
060001-) .................................................. 40-60-23
060001-) .................................................. 40-60-23
40-5
Group 05
General Information
Operation and Diagnostics information on function, operating conditions, and theory
of operation. The circuit schematics are drawn with the
The operation and diagnostics stories divide the electrical components in the operating position, with the power, or
system into individual circuits by function. Each circuit is battery positive, into them across the top and the ground,
isolated from the main wiring schematic and only shows or battery negative, across the bottom.
the components that are used in it. The story contains
Diagnostic Information • Normal reading

The diagnostic procedures is used to test the complete
• Check or test to perform if reading is not normal
circuit regardless of the problem or complaint. Select When performing the test or check, be sure to set your
a symptom or system from the quick check or machine up to the test conditions listed and follow the
troubleshooting chart and follow the test procedures under sequence carefully. performing the test or check. If the
that heading. results of the test or check are not normal, perform the
test, The diagram that accompanies each test procedure
The diagnostic procedure lists: is drawn to resemble machine components. The key letter
• Test conditions on the art matches the letter in the procedure and the
• Test sequence leader line points to the exact point the test is to be made.
• Test location
40-05-1
Group 10
Specifications
Specifications
General Specifications
Ignition Type Electronic
Starter Type Solenoid Shift
Charging System Approximate Output at 1900 rpm 36 amp
Charging System Rated Output at 6000 rpm 75 amp
Charging System Static Draw 5 ma
Regulated Voltage Voltage 13.9—14.6 V
Battery
Battery Type BCI Group U1
Battery (minimum) Voltage 12.4 V
Battery Reserve Capacity @ 25 amp 44 min.
Battery Cold Cranking Amps @ 0° F 480
Battery Negative Terminal Resistance 0.1 ohm
(maximum)
Specific Gravity (Minimum) Electrolyte Specific Gravity 1.225
Specific Gravity Electrolyte Specific Gravity 1.230—1.265
Starting Motor
Starting Motor @ 900 RPM Amperage 280 amp
Starting Motor No-Load Draw at Amperage 90 amp
3000 RPM
Speed Sensor Torque 11 N·m (97 lb-in.)
Speed Sensor Terminals Resistance 3.1k Ohms DC ±10%
IAC Terminals (A - D) and (B - C) Resistance 40—80 ohms
Knock Sensor Torque 20 N·m (177 lb-in.)
Knock Sensor Terminals (A - Resistance 1M (106) ohms
B) Minimum
Engine Coolant Temperature Sensor Torque 15 N·m (133 lb-in.)
Ignition Coil Terminals (A - B) Resistance 0.81 ohms
Ignition Coil Terminals (A - C) Resistance 10.6K ohms
Approximate
Fuel Injector Terminals (A - B) Resistance 12—16 ohm
@ 20° C (68° F)
service OBD2 Equipment and Tools

40-10-1
Specifications
Hydrometer Used to test battery specific gravity.
Battery Charger (variable rate) Used to charge battery
Battery Tester ................................. or equivalent Used to load test or test condition of battery.
Heavy Duty Jumper Cables Used to jump from battery to starting motor.
Light Duty Jumper Wire Used to jump from battery to starting motor solenoid.
Jumper Battery ........................................................... 12 V Used to test starter solenoid.
Digital Multimeter............................................... Used to measure volts, amperage, or resistance.
Current Clamp-On Probe...................................... Used with multimeter to measure staring motor current.
Hand Held Digital Tachometer.............................. Used to measure rpm.
One (1) Jumper Wire Used to test starter solenoid.
One (1) Jumper Cable Used to test starter solenoid.
12-Volt Battery Used to test starter solenoid and relays.
Ohmmeter or Continuity Tester Used to check for continuity.
40-10-2
Component Location
Pin No. Signal

61 Injector 2 Control
62 Not Used
63 ECU +12Vdc
64 Fan Relay Control
65 Fan Relay Control
66 Engine Speed Out
67 Main Relay Control Out
68 Not Used
69 Fuel Pump Relay Out
70 Malfunction Indicator Light (MIL)
71 Not Used
72 Crank Sensor Input
Coolant Temperature Sensor
73 Ground
74 Not Used
75 Not Used
76 Not Used
77 Diagnostic Data (K-Line)
78 Not Used
79 Not Used
80 Not Used
81 Not Used
40-15-3
Schematics and Harnesses
Engine Wiring Harness (SN 060001-)
Diagnostic
Port
4 - 120 Blk
1 - 001 Blk 44 - 44 Gry/Red
7 - 77 Wht/Grn
2 - 002 Blk 45 - 45 Grn
16 - 121A Red Splice
3 - 3 Grn 46 - 46 Blu/Wht
4 - 4 Brn/Yel 48 - 48 Blk/Wht 55 Blk
5 - 5 Blu/Grn 51 - 51 Blk/Wht 55A Blk
8 - 8 Grn 54 - 54 Pur/Wht ECU 55B Blk
10 - 10 Grn/Red 55 - 55 Black 55C Blk
19 - 19 Blu 56 - 56 Yel
20 - 20 Wht 59 - 59 Blk
21 - 21 Red 60 - 60 Red/Blk
22 - 22A Yel 61 - 61 Brn/Blu
23 - 23 Brn/Wht 63 - 63 Gry/Red
24 - 24 Brn/Grn 64 - 64 Org
27 - 27 Brn/Blk 65 - 65 Org 6 24
29 - 29 Blu/Grn 66 - 66 Yel
30 - 30 Grn/Org 67 - 67 Grn
31 - 31 Blu 69 - 69 Grn
32 - 32 Red/Wht 70 - 70 Grn
35 - 35 Grn 72 - 72 Pnk 5 4
36 - 36 Blu/Red 73 - 73 Brn 3
38 - 38 Blk 77 - 77 Wht/Grn 2 1
43 - 43 Pur/Blk 63 81
Knock
Ignition
Ignition Ignition Sensor
Coil #1 Fuel Injector #3
Coil #2 Coil #3
1 - 4 Brn/Yel 1 - 23 Brn/Wht
1 - 5 Blu/Grn
2 - 103C Org 1 - 3 Grn 2 - 104D Red
2 - 103B Org
2 - 103A Org
1 - 54 Pur/Wht
2 - 10 Grn/Red
Splice
Crank
103 Org
Position 103A Org
Sensor 103B Org
103C Org
1 - 104F Red
2 - 29 Blu/Grn
3 - 27 Brn/Blk
Cam
Position
Water
Sensor
Temp
Sensor 1 - 104E Red
2 - 30 Grn/Org
1 - 31 Blu 3 - 72 Pnk
2 - 90 Red
3 - 73 Brn
Engine harness (1 of 2)
40-22-22
Schematics and Harnesses (SN 060001-)
Engine Wiring Harness (SN 060001-)
Splice to Main
22A Yel Harness 1 - A44 Pur 9 - 22B Yel
22B Yel 2 - 70 Grn 10 - 65 Org
A17 Red/Wht 3 - 82 Wht 11 - 120 Blk 8 1
4 - 83 Brn 12 - 51 Blk/Wht
5 - 64 Org 13 - 69 Grn
6 - 90 Red 14 - 121B Red
7 - 67 Grn 15 - 66 Yel 16 9
8 - 104 Red 16 - 103 Org
Splice
44 Gry/Red
63 Gry/Red
121A Red
Battery +
Starter
121B Red 81A Red
Motor Alternator
81A Red 1 - A17 Red/Wht
81B Red 2 - 82 Wht
1 - 8 Grn
2 - 59 Blk
1 - 35 Grn 3 - 104G Red
2 - 19 Blu 4 - 43 Pur/Blk
3 - 20 Wht
21 Red
4 - 36 Blu/Red Oxygen
104 Red
Idle Air Sensor 104B Red
Control 104C Red
104D Red
Alternator + 104E Red
104F Red
81B Red
104G Red
Splice
Fuel Injector #2 Ground

1 - 61 Brn/Blu
001 Blk
2 - 104C Red
002 Blk
Fuel
TMAP Sensor Injector
1 - 60 Red/Blk Oil
2 - 46 Blu/Wht #1 Throttle
3 - 56 Yel 1 - 24 Brn/Grn Position Pressure
Starter Motor 4 - 48 Blk/Wht 2 - 104B Red Sensor Switch
1 - 32 Red/Wht
Solenoid 83 Brn
2 - 45 Grn
A44 Pur 3 - 38 Blk
Engine harness (2 of 2)
40-22-23
Schematics and Harnesses
Size/No./Color Wire Connection Points

Engine Wiring Harness Color Codes (SN
16.0 081A Red Start Motor, Bat +
060001-)
8.0 081B Red Alt, Start Motor
Size/No./Color Wire Connection Points
0.8 082 Wht Alt Discharge, Main Harness
2.0 001 Blk ECU, Gnd
0.8 083 Brn Oil Pressure Switch, Main Harness
2.0 002 Blk ECU, Gnd
0.8 090 Red Temp Switch, Main Harness
2.0 003 Grn ECU, Ign Coil 3
0.8 103 Org Main Harness, Splice
2.0 004 Brn/Yel ECU, Ign Coil 1
0.8 103A Org Ign Coil 3, Splice
2.0 005 Blu/Grn ECU, Ign Coil 2
0.8 103B Org Ign Coil 2, Splice
0.8 008 Grn ECU, O2 Sensor
0.8 103C Org Ign Coil 1, Splice
0.8 010 Grn/Red ECU, Knock Sensor
0.8 104 Red Main Harness, Splice
0.8 019 Blu ECU, IAC
0.8 104B Red Inj 1, Splice
0.8 020 Wht ECU, IAC
0.8 104C Red Inj 2, Splice
0.8 021 Red ECU, Splice
0.8 104D Red Inj 3, Splice
0.8 022A Yel ECU, Splice
0.8 104E Red Cam Sensor, Splice
0.8 022B Yel Main Harness, Splice
0.8 104F Red Crank Sensor, Splice
0.8 023 Brn/Wht ECU, Inj 3
0.8 104G Red O2 Sensor, Splice
0.8 024 Brn/Grn ECU, Inj 1
0.8 120 Blk Diag Port, Main Harness
0.8 027 Brn/B k ECU, Crank Sensor
0.8 121A Red Diag Port, Splice
0.8 029 Blu/Grn ECU, Crank Sensor
0.8 121B Red Main Harness, Splice
0.8 030 Grn/Org ECU, Cam Sensor
0.8 A17 Red/Wht Alt Field, Splice
0.8 031 Blu ECU, Temp Sensor
0.8 A44 Pur Start Solenoid, Main Harness
0.8 032 Red/Wht ECU, TPS
0.8 035 Grn ECU, IAC
0.8 036 Blu/Red ECU, IAC
0.8 038 Blk ECU, TPS
0.8 043 Pur/B k ECU, O2 Sensor
0.8 044 Gry/Red ECU, Splice
0.8 045 Grn ECU, TPS
0.8 046 Blu/Wht ECU, TMAP
0.8 048 Blk/Wht ECU, TMAP
0.8 051 Blk/Wht ECU, Main Harness
0.8 054 Pur/Wht ECU, Knock Sensor
0.5 055 Blk ECU, Splice
0.5 055A Blk Ign Coil 1 Shield, Splice
0.5 055B Blk Ign Coil 2 Shield, Splice
0.5 055C Blk Ign Coil 3 Shield, Splice
0.8 056 Yel ECU, TMAP
0.8 059 Blk ECU, O2 Sensor
0.8 060 Red/Blk ECU, TMAP
0.8 061 Brn/Blu ECU, Inj 2
0.8 063 Gry/Red ECU, Splice
0.8 064 Org ECU, Main Harness
0.8 065 Org ECU, Main Harness
0.8 066 Yel ECU, Main Harness
0.8 067 Grn ECU, Main Harness
0.8 072 Pnk ECU, Cam Sensor
0.8 073 Brn ECU, Temp Sensor
0.8 077 Wht/Grn ECU, Diag Port
40-22-24
Operation and Diagnostics
Power Circuit Operation The battery cables and the starting motor tie point
Function: connections must be good for the machine electrical
system to work properly. The ground cable and positive
To provide unswitched and switched power to the primary cable connections are equally important. Proper starting
electrical components whenever the battery is properly motor operation depends on these cables and connections
connected. to carry high current.
The power circuits are divided among the unswitched Switched Power:
power circuit, switched power circuits (key switch in run
position), and secondary power circuits. The secondary In addition to the voltage present at the locations of the
power circuits become energized when switched power unswitched power circuits, voltage must be present at the
circuits energize relays and/or control modules, providing following components during the following conditions:
current paths to the secondary circuits. The secondary
power circuits will not be energized if the relay or control
• Key switch S3
module controlling the current path(s) fail.
• Front attachment C-5
• E-MFWD lock solenoid C-35
NOTE: The following description only encompasses • A2 Relay module C-50 (J3)
the components that should always have power • Display panel C-26 (J1)
with the key switch on. Many other components • Brake switch C-32
will likely have power, but that is dependent • Brake switch C-88
on operating conditions. • Park brake switch
• Reverse switch C-20
Unswitched Power: • C-28 connector
• Park brake switch T-9
Voltage must be present at each of the following • Engine connector C-19
components with the key switch in the off position: • 4WD switch C-34
• Battery positive terminal • Light switch C-7
• Start motor BAT terminal • Neutral switch C-12
• All fuses on quad fuse block (both sides) C-13 • Seat belt switch C-4
• C-38 connector • EPAS relay C-97
• Relay module C-8 (J1) These circuits are controlled by the key switch and are
• C-6 Front power protected by the fusible link and the 15A fuse located in
• C-10 Rear power the relay module.
• Display panel C-26 (J1)
• Key switch S3 Secondary Power:
The positive battery cable connects the battery to the See individual circuit descriptions for secondary power
starting motor. The starting motor bolt is used as the 12 circuit functions i.e. ECU, relay outputs, relay module
Volt DC tie point for the rest of the electrical system. outputs, etc.
Power Circuit Diagnosis
Unswitched Power

40-25-1
Cranking Circuit Operation will then allow power to flow over the 705 Pur wire to the
“key switch crank” input (J3, pin 4 - “key switch crank”)
Function: of the relay module. This tells the internal logic that the
To energize the starting motor solenoid and engage the operator wants to crank the engine.
starting motor to crank the engine. Additionally, with the neutral switch closed, battery voltage
is transmitted from the S2 terminal of the key switch over
Operating Conditions:
the 711 Pur wire to the the relay module (J3, pin 10). With
• Key switch in start position the “key switch crank” and ‘neutral switch input” signals
• Transmission in neutral both present, the relay module logic will output a 12 volt
signal (J2, pin A - “start solenoid driver”) to the engine
Theory of Operation: wiring harness and then on to the start solenoid.
The only safety related cranking circuit operating This will energize the start solenoid to close its contacts.
requirement if that the transmission must be in neutral. The A44 Pur wire connects to the starting motor solenoid
This interlock is achieved two ways: to energize the starting motor solenoid. With the starting
motor solenoid energized, the starting motor solenoid
The first interlock is electro-mechanical. With the machine contacts close and high current from the battery passes
in neutral, the now closed neutral switch will transmit through the battery cable and solenoid contacts to the
battery voltage over the 710 Pur wire to the S2 terminal of starting motor. The starting motor cranks the engine.
the key switch. With the key switch in the crank position, it
40-25-12
Charging Circuit Diagnosis • Battery fully charged.

• Open hood and remove storage tray.
Charging Circuit Diagnosis Test • Disconnect any other attachment option(s) from the
main wiring harness.
Procedure: • Key switch in RUN position, engine not running.
• Test Conditions • If diagnosis fails to correct problem, use service OBD2
ADVISOR, or find relevant OBD diagnostics in this
• Machine parked safely. See Park Machine Safely. manual, or see your dealer.
• Cargo box raised and locked.
Alternator Circuit
Step 1
A—208 Red Wire YES: Go to next step.

B—420Y/420J Yel Wires
Is battery voltage present at connector terminal “B” of the S3 key switch, 208 Red NO: Check F11 fuse, 206,
wire (A)? 201, 202 and 208 Red
wires, 218 fuse link and
connections.
Step 2 Is battery voltage present at terminal “A”, 420Y/420J Yel wires (B)? YES: Go to next step.
NO: Test key switch. See
Key Switch Test.
40-25-18
Oil Pressure Light Circuit Operation With the engine not running or under low oil pressure
conditions, this switch will ground, thereby completing the
circuit and the display panel light will illuminate.
Function:
With the engine running and adequate engine oil pressure
To indicate to the operator engine oil pressure status. is present, the switch will remove the path to ground and
Operating Conditions: the light will extinguish.
The OPS circuit also controls the hour meter. If no oil
• Key switch in run position pressure is present (switch closed), the hour meter will
• Engine running or not running not increment.
Theory of Operation:
Other than the visual indicator, the OPS has no vehicle
The display panel outputs battery voltage to over the 601 protection logic function.
Tan wire (J1, pin G) to the C-19 connector. Then, on the
engine harness side, the circuit becomes the 83 Brn wire.
This connects to the oil pressure switch (OPS).
40-25-35
Cooling Circuit Operation The fan motor is grounded by the 100A Blk wire to the
100-series ground bus.
Function:
Cooling fan operation continues until the engine
To provide an input to the electronic control unit to process temperature drops below 88°C (190°F).
and supply the appropriate outputs to manage the radiator
fan, engine coolant temperature warning light, and the Theory of Operation - Coolant Temperature Light:
fuel system. Also provides a signal to the display panel’s
LCD temperature gauge. When the ECU senses that the coolant temperature
exceeds 110°C (230°F), it sends a LO signal to the display
Theory of Operation - Coolant Temperature Sensor: panel via the 64 Org and 305 Pnk wires. This signal
allows the display panel to illuminate and flash the coolant
The coolant temperature sensor contains two thermistors. temperature warning light.
A thermistor is a semiconductor device having a resistance
that decreases rapidly with an increase in temperature. The temperature warning light continues to flash until the
engine temperature drops below 100°C (212°F).
One thermistor is used exclusively by the ECU to control
the cooling fan, engine operation, and the coolant NOTE: The ECU will go into “limp home mode”to
temperature warning light. The remaining thermistor is protect the engine. Reduced performance will
connected to the display panel temperature gauge. result.
Although physically housed in the same sensor, the two Theory of Operation - Temperature Gauge:
thermistors are electrically isolated.
The temperature gauge is an LCD bar graph display that
Theory of Operation - Cooling Fan: receives an analog signal from the temperature sensor
via the 090 Red and 300 Org wires. This circuit works
As the coolant temperature approaches 95°C (203°F),
independently from fan and temperature light operation.
the ECU sends a ground level (“LO”) signal via the 65
and 310 Org wires to the Relay Module fan switch input. The variable resistance from the coolant temperature
One side of the fan relay coil has switched battery voltage sensor is processed within the display panel by an
(V_EL) with the key switch on. The LO signal grounds analog-to-digital (A/D) converter. The resultant digital
the opposite end of the coil, energizing the relay. Battery signal is then used to operate the temperature gauge bar
power from the 30A fan fuse flows via the relay contacts graph.
and 315 Org wire to the C-22 cooling fan connector.
Cooling Circuit Electrical Diagnosis
Service OBD2 or OBD code is required for

diagnosing this system.
40-25-36
Troubleshooting Electronic Controllers

Problems Due to Intermittent Electrical Failures:
NOTE: This reference is a guideline for troubleshooting NOTE: Electrical intermittent failures are
problems that still exist after standard diagnostics usually caused by harness, terminal or
have been performed. These problems are connector problems.
typically due to specific operating conditions,
intermittent failures or, in rare cases, control unit • Inspect all connectors and terminals of related circuits.
failures. Depending on the situation, some or all • Inspect mechanical linkages for interference with
of the following may be important. harnesses or connectors.
• Inspect harnesses for missing or improperly installed
Problems Due to Specific Operating Conditions: clamps or bands. Loose harnesses that are allowed to
move too freely or harnesses that are banded too tightly
Review all recorded codes and consult with operator may result in worn or damaged wires.
to determine operating and vehicle conditions when the • Inspect mechanical linkages for proper operating
problem occurs. Record details. condition.
• Does code/problem occur at the same time as other Problems Due to Control Unit Failures:
problems?
• Does code/problem occur when vehicle is warm or cold? NOTE: Before replacing control unit, review all tests.
• Does code/problem occur during field or transport Control units are the least likely cause of failure!
operation?
• Does code/problem occur while performing a specific • If all checks have been made with no problems identified,
action such as shifting, turning, braking, operating check power and ground circuits. Power inputs must be
certain hydraulics? within 1 V of battery voltage and ground circuits must
• When did code/problem first appear? Was there any be less than 1.0 ohm to the vehicle single point ground.
maintenance performed recently? (If yes, inspect areas • Do not confuse low side driver (LSD) or dedicated
of maintenance for inadvertent damage or improper sensor/control grounds with frame ground. These
installations.). grounds or LSDs are often at a higher potential than
frame ground.
Attempt to recreate code/problem based on conditions. If • Inspect all connectors and terminals of associated
possible, repeat operational, system, electrical, hydraulic control units.
or mechanical checks under these conditions.
On Board Diagnostics • B = Body

Diagnostic Trouble Codes (DTCs):
• C = Chassis
2nd Digit:
The ECU is capable of recording current or stored DTCs
to its memory. If a malfunction exists, it will turn on • 0 = Standard
the malfunction indicator . It indicate that a problems • 1 = Manufacturer Specific
exists. In order to display the specific DTC(s), service 3rd Digit:
OBD2 ADVISOR must be connected to the machine.
• 1 = Emission Management
An industry standard ISO 9141-2 serial communication • 2 = Injector Circuit
protocol is used for DTC retrieval. • 3 = Ignition
• 4 = Auxiliary Emission
Description of Code Structure: • 5 = Vehicle Speed & Idle Control
• 6 = Computer and Output Circuit
Sample Code: P0031 • 7 = Transmission
Code digit position - 1 2 3 4 5 The remaining digits describe the specific malfunction
which may or may not be industry standards.
1st Digit:
• P = Powertrain
40-25-56
Group 30
Operation and Diagnostics - Fuel Injection
Summary of References • Fuel Injector Operation
• Temperature/Mass Air Pressure (TMAP) Sensor Circuit • Fuel Pump Operation
Operation
• Malfunction Indicator Light (MIL) Operation
• Throttle Position Sensor (TPS) • Diagnostic Interface Circuit Operation
• Coolant Temperature Sensor Circuit Operation • Electronic Control Module/Relay Module (ECM)
Operation
• Knock Sensor Circuit Operation • ECU Sensor and Diagnostic Circuit Diagnosis
• Oxygen Sensor (O2) Circuit Operation • Fuel Injection Circuit Electrical Schematic (SN -060000)
• Idle Air Control Motor (IAC) Circuit Operation • Fuel Injection Circuit Electrical Schematic (SN 060001-)
• Ignition Coil Operation
Temperature/Mass Air Pressure (TMAP) Temperature Function:

Sensor Circuit Operation
From the ECU, the 56 Yel wire (pin 56) goes to the TMAP
Function: sensor (5Vdc). Internal to the sensor is a thermistor which
changes its resistance according to ambient temperature.
To provide the ECU with engine load information as well As the temperature increases, the resistance decreases.
as intake air temperature measurement. The signal is returned to the ECU via the 48 Blk/Wht wire
Operating Conditions: (pin 48). An internal algorithm translates this return signal
into an actual temperature.
• Key switch in run position Air Pressure Function:
• Engine running
From the ECU, the 46 Blu/Yel wire (pin 46) goes to the
TMAP sensor (5Vdc). Internal to the sensor is a silicon
This sensor has two related functions. One is to measure chip that will deform when varying amounts of pressure
air flow through the intake manifold and the other is are applied to it. This, in turn, will change its resistance
to measure air temperature. From this, the ECU can and thereby, its output. The signal is returned to the ECU
determine air density and relative engine load. The ECU via the 60 Red/Blk wire (pin 60). An internal algorithm
uses this information, as well as inputs from other sensors, translates this return signal into a pressure reading.
to provide control for optimum engine performance.
Due to the fact that air density changes as a result of
temperature, both internal sensors must be functioning
properly.
Throttle Position Sensor (TPS) The ECU outputs 5Vdc over the 45 Grn/Blk wire (pin 45)
Function: to the TPS. The sensor is grounded by the 38 Blk wire (pin
38). Signal output to the ECU is via the 32 Grn/Wht wire
To indicate to the ECU engine throttle position. (pin 32). The sensor uses an internal wiper that slides on
a resistive element that will change its output based upon
Operating Conditions: the wiper’s position. This wiper is physically connected
to the throttle shaft. An internal algorithm translates this
• Key switch in run position output to measured throttle position.
• Engine running
Sensor measures throttle position and the ECU uses
this information, as well as inputs from other sensors, to
provide optimum engine performance.
40-30-1
Coolant Temperature Sensor Circuit The ECU outputs 5Vdc on the 31 Blu wire (pin 31) to the
Operation sensor. A sensor signal output is provided by the 73 Brn
wire (pin 73). The sensor also outputs this information to
Function:
the machine via the 90 Red wire to the display panel to
To provide the ECU with coolant temperature data. drive the LCD coolant gauge. The 90 Red wire circuit will
The ECU uses this information, as well as inputs from become the 300 Org wire feeding the display panel input.
other sensors, to provide control for optimum engine The temperature sensor driver is controlled by a thermistor
performance in which the resistance decreases as coolant temperature
Operating Conditions: increases. This resistance change is not proportionally
linear to temperature change. Resistance should be 2.45
• Key switch in run position K-ohms at 20° C (68° F) and 50 ohms at 80° C (176° F).
• Engine running If the temperature exceeds an unsafe limit, the ECU will
Theory of Operation: direct the engine to operate in “limp home mode”.
The ECU uses coolant temperature information, along

with other sensor inputs, to control ignition timing and fuel
injection pulse width control.
Knock Sensor Circuit Operation distortions of the element occur and voltage pulses
are induced into the signal line back to the ECU. If the
Function: amplitude of these pulses become strong enough, the
Allows the ECU to determine if engine pre-ignition is ECU will detect this as pre-ignition and the ECU will retard
occurring and adjust ignition time accordingly. ignition timing until the knock is no longer present. At that
point, the ECU will advance ignition timing to its normal
Operating Conditions: level. If timing is retarded past a maximum preset value,
the ECU will direct the engine to operate in “limp home
• Key switch in run position mode”.
• Engine running
The 10 Grn wire (pin 10) provides the ECU with cylinder
Theory of Operation: firing pulses. The 54 Pur/Wht wire supplies the ground
path.
The knock sensor consists of a piezeo electric element
encased in a mass block. As the cylinders fire, slight
Oxygen Sensor (O2) Circuit Operation Switched power is supplied to heater via the 104 Red
Function: series wires. After the sensor connector, this circuit will
become a Wht wire. Ground and low side circuit control
The oxygen sensor is mounted in the engine exhaust is accomplished by the ECU over the 8 Grn wire (pin
stream and informs the ECU if the spent air/fuel mixture 8). This will terminate as a Wht wire at the sensor as
has burned completely. well. The ECU will use the low side control to maintain a
temperature of 300° C (572° F).
Oxygen Sensor:
• Key switch in run position
• Engine running The ECU receives a self generated signal from the sensor
over the 59 Blk wire (pin 59) that will range between 0.1 -
Theory of Operation: 0.9 VDC only when the machine is running. 0.45 VDC is
when the engine is running at an ideal air/fuel mixture. This
The O2 sensor consists of two basic elements. One is the signal is very difficult to measure with a digital multimeter
sensor itself, and the other is a heating element to keep as the voltages fluctuate so much and so quickly. It’s best
measurements consistent as well as speed up the time just to determine if the voltages are within range. Ground
before it can come into use on a cold engine. for the sensor is provided by the 43 Pur/Blk wire (pin 43).
Heating Element:
40-30-2
Idle Air Control Motor (IAC) Circuit Operation Theory of Operation:

Function:
The ECU takes into account inputs (such as engine load,
The IAC controls idle speed via the ECU. temperature, air flow, etc.) and adjusts the engine speed
accordingly.
The IAC consists of a 2-coil stepper motor coupled to an air
• Key switch in run position valve plunger. The ECU sequentially alternates the coils’
• Engine running polarity as needed in order to move the plunger in or out.
The coils receive signal voltage over the 35 Grn and 19
Blu wires (pins 36 and 19) and return is supplied via the
36 Blu/Red and 20 Wht wires (pins 26 and 20).
Both coils must be working properly for the IAC to function.
Ignition Coil Operation sensors. The coils are low side (ground) switched. There
are no self diagnostic functions for the ignition coils, only
Function: an indicator if there is a problem.
To create an ignition spark at the correct time and duration. Power to all coils is continuously supplied by the 103
series Org wires coming from the relay module. The
following wires provide ignition coil control:
• Key switch in run position • Coil 1: 4 Brn/Yel (pin4)
• Engine running • Coil 2: 5 Blu/Grn (pin 5)
Theory of Operation: • Coil 3: 3 Grn (pin 3)
The ignition coils are completely controlled by the ECU. Noise interference is suppressed by the 55 Blk (pin 55)
ECU control is based on input from various other engine shield.
Fuel Injector Operation Theory of Operation:

Function:
The ECU controls all aspects of the fuel injectors based
To provide proper quantity and duration of fuel to the on inputs from other engine sensors. Current through
engine. the injectors is managed with low side (ground) switched
modulation. There are no self diagnostic functions for the
Operating Conditions: fuel injectors, only the control circuits.
• Key switch in run position Power to all injectors is supplied by the 104 Red series
• Engine running wires. The following wires provide injector control:
• Injector 1: 24 Brn/Grn (pin 24)
• Injector 2: 61 Brn/Blu (pin 61)
• Injector 3: 23 Brn/Wht (pin 23)
Fuel Pump Operation Theory of Operation:

Function:
The fuel pump is controlled by the ECU. The ECU will only
To provide fuel, under the correct pressure, to the engine. drive the fuel pump during cranking and normal operation.
If a serious engine malfunction is detected, the ECU will
Operating Conditions: remove power to the fuel pump. Circuit operation for
the fuel pump can be found in the Fuel pump Theory of
• Key switch in run or crank position Operation.
• Engine running
40-30-3
Diagnostic Interface Circuit Operation as the “K-Line”. This connector complies with the ISO
9141-2 standard. With service OBD2 ADVISOR
Function: connected to the machine, active or stored DTCs can
To allow a connection to service OBD2 ADVISOR to be downloaded from the ECU.
assist diagnosis by viewing diagnostic trouble codes OBDC pinout:
(DTCs) via the on board diagnostic connector (OBDC).
The OBDC is an industry standard. • 120 Blk (pin 4 on OBDC) Gnd
• 121 Red (pin 16 on OBDC) Vbat
Operating Conditions: • 77 Wht/Grn (pin 7 on OBDC to pin 77 on ECU) K-Line
• Key switch in run position, engine running or not running The K-line idles high (Vbat when no data is being
transmitted). A logic low will be 30% of Vbat and a
Theory of Operation: logic high will be 70% of Vbat. After all data has been
The OBDC consists of a power circuit (Vbat), ground, transmitted, the K-line will return to idle Vbat.
and a serial RS232 bi-directional data circuit known
40-30-4
Electronic Control Module/Relay Module When operating conditions have been met, the ECM
(ECM) Operation distribute power to various components depending upon
operator preference, ECU commands, or operating
Function:
conditions.
Provides fused power distribution to various components Also, either directly or indirectly (ECU command), the
as well as processing certain inputs and outputs for ECM controls these functions:
discrete components and the ECU.
The ECM does not have a driver to cause the malfunction
• Ignition coil supply
indicator light (MIL) to illuminate, but has components and
• ECU power
circuitry that may cause the ECU to turn on the MIL.
• Cooling fan
• Start motor
Operating Conditions: • Fuel pump
• 4WD
• Key in run or start position, •Seatbelt lamp
• Engine running. • Monitoring of machine speed (shared with display panel
Theory of Operation: and EPAS)
Power is supplied to the electronic control module (ECM) With the exception of fuse replacement, the ECM is not
when key is in the run or start position. serviceable.
ECU and General Sensor Circuit Operation components are based on the ECU reading an out of
range voltage, or either an open or a shorted circuit. This
Function: means that the ECU is receiving either greater than 5
Sensors provide the inputs to the ECU, which in turn VDC or less than 1.0 VDC from the sensors.
provides the proper output to the injectors and ignition When the key switch is turned to the off position the fault
coils. is stored in memory.
These fault codes (as viewed through service OBD2
ADVISOR) will aid in the diagnosis of operational
problems that may occur.
• Key in run or start position.
• Engine running.
The ECU also has many different fault codes available to
assist with diagnostics. If a malfunction is displayed, this
Power is supplied to the engine electronic control unit means that the ECU is receiving an erroneous voltage
(ECU) when the key is in the run or start positions and the signal, no voltage, an open or closed circuit, or a trigger
main engine control relay has been energized. voltage from a sensor or component.
When the operating conditions have been met, the ECU Once a code has been read through service OBD2 , it
sensors provide inputs to the ECU so that the ECU can be matched to the fault code chart to assist in
will provide the ground path (low side switched) for the diagnosis.
injectors at the correct time and duration.
Limp Home Mode:
The ECU also has a self diagnostic mode that will display
a code through service OBD2 and illuminate the When the ECU detects a malfunction that may cause
onboard warning light if any of the input sensors, injectors, engine damage, it shuts off fuel and the ground for the
or ignition coils are not operating properly. When the rear cylinder ignition coil. This allows the engine to run,
circuit is operating normally, this light will remain off. in a reduced capacity, to prevent engine damage and to
allow the machine to be driven to a safe location.
The engine sensors are all components that change their
signal outputs to the ECU. The fault codes for these
40-30-5
Fuel Injection Circuit Electrical Schematic
208 Red
20A
D4 D3
556 Red
10A
C1 C2
3A
D5 D6
S3
Key
205W Red
205A Red
205X Red
550 Grn
226 Red
Switch Off
Run
Start
85 30 K03
Fuel S1 S2
Pump
87a
S-12 86 87 Relay 420J Yel A B 208 Red
M G
555 Blu >

C-29
100C Blk > to Fuel
Pump
S-1
C-19
205 Red
420V Yel S-2 422X Yel J 9 22B Yel
699 Red 699 Red A 8 104 Red
101Z Blk
420D Yel
T-12
Ground
C-50 / J1
Ground 1
669 Brn B 7 67 Grn
Main Power Relay SW 2
Key “ON” Power 3
Neutral Switch Input 4
Throttle Switch Input 5
Seat Belt Lamp Driver 6
Speed Sensor Input 7
Seat Belt Input 8
Park Brake Buzzer 9
Speed Sensor Out 10
Extra Relay Drive Sink 11
202 Red
S-6 4WD Switch Input 12
Load Shed 13
Key Switch Crank 14
4WD Solenoid Driver 15
201
A B+
A1 Relay
B Glow Plugs
Module
C V_EL
+ 550 Grn N 13 69 Grn
D Ignition Coil Supply
G1 C-8 / J3 226 Red P 14 121B Red

- Battery
689 Red 689 Red S 16
100 Blk
T-7 550 Grn

Frame
Ground 226 Red 103 Org
40-30-12
104 Red
22A Yel
61 Brn/Blu
59 Blk
55 Blk
54 Pur/Wht
1 Blk
Injector GND 1
2 Blk }ES-12
49-50-51 3 Grn
52-53 ECU PWR GND 2
4 Brn/Yel
Not Used IGN Coil 3 3
55 Blk 5 Blu/Grn
54 Knock Sense GND IGN Coil 1 4
56 Yel
55 IGN Coil Shield IGN Coil 2 5
56 Intake Air Temp In CAN Lo 6 8 Grn
59 Blk 57 Not Used CAN Hi 7
60 Red/Blk 58 Not Used O2 Heat PWM 8 10 Grn/Red
59 O2 Up (-) Not Used 9
60 MAP In Knock Sense In 10
63 61 INJ 2 Cntl
Gry/ 62 Not Used Knock
Red 63 ECU (+12Vdc) Not Used Sensor
64 Fan Rly (Hi) 11-12-13
65 Fan Rly (lo) 14-15-16
66 Engine Spd Out 17-18
67 Main Rly Cont Out 19 Blu
68 Not Used 20 Wht
69 Fuel Relay Out Idle A Hi 19 21 Red
70 Trouble Lamp Idle A Lo 20 22A Yel
71 Not Used V_EL +12Vdc 21 23 Brn/Wht
72 Cam Pos In V_IG +12Vdc 22 24 Brn/Grn
73 Coolant Temp GND INJ 3 Cntl 23
22B Yel
74 Not Used INJ 1 Cntl 24 43 Pur/Blk
75 Not Used Not Used 25 27 Brn/Blk
104 Red
76 Not Used Not Used 26
77 Diagnostic Data Crank Pos GND 27 29 Blu/Grn
Not Used Not Used 28 30 Grn/Org
78-79 Crank Pos In 29
80-81 31 Blu
CAM Pos GND 30 32 Grn/Wht
Coolant Temp In 31
67 Grn
TPS In 32
Not Used 33 35 Grn
Not Used 34 36 Blu/Red
Idle B Hi 35
A3 Idle B Lo 36 38 Blk
ECU Not Used 37
TPS GND 38
39-40
41-42
Not Used 43 Pur/Blk
O2 Up (+) 43 45 Grn/Blk
ECU (+12Vdc) 44 46 Blu/Yel
TPS VCC 45
MAP VCC 46 48 Blk/Wht
Not Used 47
MAP GND 48 Coolant
t˚
69 Grn 73 Brn Temp
44 Gry/Red Sensor
121B Red 72 Pnk
60 Red/Blk
56 Yel
103 Org
40-30-13
104 Red
61 Brn/Blu
59 Blk
55 Blk S-11
55C Blk
55B Blk
3 Grn 55A Blk Ignition Coils

3 Grn
4 Brn/Yel 4 Brn/Yel
5 Blu/Grn 5 Blu/Grn
#3
Shields #1
8 Grn #2
104G Red
Wht
Gry O2 Sensor
103C Org
Wht
Blk
Spark 103B Org 103A Org

Plugs
19 Blu
20 Wht Fuel Injectors
21 Red
#3
23 Brn/Wht 23 Brn/Wht 104D Red
24 Brn/Grn
104E Red
43 Pur/Blk
24 Brn/Grn
27 Brn/Blk
3
Crank
2 Cam
29 Blu/Grn Sensor
1 Sensor
30 Grn/Org #1
104F Red 104B Red
1
32 Grn/Wht
2
3
35 Grn
36 Blu/Red
38 Blk #2
104C Red
C B
Throttle
D A
Position
Sensor Idle Air Control 61 Brn/Blu
45 Grn/Blk
46 Blu/Yel
48 Blk/Wht
72 Pnk
60 Red/Blk
56 Yel
TMAP
Sensor
103 Org
40-30-14
Group 35
Operation and Diagnostics - DTCs
Error Codes List P0265 Cylinder 2 - Injector Circuit High
P0031 O2 Sensor Heater Circuit Low (Bank1 Sensor 1) P0267 Cylinder 3 - Injector Circuit Low
P0032 O2 Sensor Heater Circuit High (Bank1 Sensor 1) P0268 Cylinder 3 - Injector Circuit High
P0107 Manifold Absolute Pressure Circuit Low Input P0325 Knock Sensor 1 Circuit Malfunction
P0108 Manifold Absolute Pressure Circuit High Input P0335 Crankshaft Position Sensor Circuit Malfunction
P0112 Intake Air Temperature Circuit Low Input P0340 Camshaft Position Sensor Circuit Malfunction
P0113 Intake Air Temperature Circuit High Input P0351 Ignition Coil 'A' Primary Secondary Circuit
P0116 Engine Coolant Temperature Circuit Malfunction
Range/Performance P0352 Ignition Coil 'B' Primary Secondary Circuit
P0117 Engine Coolant Temperature Circuit Low Input Malfunction
P0118 Engine Coolant Temperature Circuit High Input P0353 Ignition Coil 'C' Primary Secondary Circuit
Malfunction
P0119 Engine Coolant Temperature Circuit Intermittent
P0505 Idle speed actuator command signal incorrect
P0122 Throttle Position Sensor/Pedal Position Circuit
Input Low P0506 Idle Control System – RPM lower than expected
P0123 Throttle Position Sensor/Pedal Position Circuit P0507 Idle Control System – RPM higher than expected
Input Low P0560 System Voltage Problem
P0130 O2 Sensor Circuit Malfunction ( Bank 1 Sensor 1) P0605 Internal Control Module Read Only Memory (ROM)
P0131 O2 Sensor Circuit Low Voltage ( Bank 1 Sensor 1) Error
P0132 O 2 Sensor Circuit High Voltage (Bank 1 Sensor 1) P0650 Malfunction Indicator Lamp (MIL) Control Circuit
P0134 O 2 Sensor No Activity Detected (Bank 1 Sensor 1) P1166 O 2 Sensor – Controller Adaptation Diagnosis
Malfunction
P0230 Fuel Pump Circuit Malfunction
P1624 Cooling Fan Relay – Circuit Malfunction – "Low"
P0261 Cylinder 1 - Injector Circuit Low Circuit
P0262 Cylinder 1 - Injector Circuit High P1625 Cooling Fan Relay – Circuit Malfunction – "High"
Circuit
P0264 Cylinder 2 - Injector Circuit Low
40-35-1
Error Codes Description

Error Code Description Purpose Error Code Description Description
P0031 O2 Sensor Heater The purpose of the P0131 O2 Sensor Circuit O2 sensor output
Circuit Low (Bank 1 diagnosis is to detect Low Voltage (Bank1 always near zero volts.
Sensor 1) electrical faults within Sensor 1)
P0032 O2 Sensor Heater the oxygen sensor P0132 O2 Sensor Circuit O2 sensor output is
Circuit High (Bank 1 heater circuit High Voltage (Bank1 always above 1 volt.
Sensor 1)
• Short circuit Sensor 1)
to Vbat by P0134 O2 Sensor No Activity O2 sensor output is
Over-temperature Detected (Bank1 consistently near 0.3
or Over current Sensor 1) volts.
(SCB)
P0230 Fuel Pump Circuit The purpose is to
• Short circuit to GND
Malfunction diagnose the electrical
(SCG)
fuel pump relay control
• Open load (OL)
signal from the driver
P0107 Manifold Absolute The purpose is to which controls the
Pressure Circuit Low diagnose the analog electrical fuel pump
Input input signal from relay.
P0108 Manifold Absolute manifold air pressure
P0261 Cylinder 1 - Injector The driver circuit for
Pressure Circuit High sensor. Two errors
Circuit Low the injector(s) is either
Input can be detected by
P0264 Cylinder 2 - Injector open or shorted to
range-check: “Short
Circuit Low ground.
to Ground or Open
Circuit“ and “Short to P0267 Cylinder 3 - Injector
Battery “. Circuit Low
P0112 Intake Air The purpose is to P0262 Cylinder 1 - Injector The driver circuit for
Temperature Circuit diagnose the analog Circuit High the injector(s) is either
Low Input input signal (TIA) shorted to battery or
from the intake air P0265 Cylinder 2 - Injector
P0113 Intake Air Circuit High overloaded.
Temperature Circuit temperature sensor to
High Input the micro controller. P0268 Cylinder 3 - Injector
Circuit High
P0116 Engine Coolant The purpose of
Temperature Circuit this diagnosis is to P0325 Knock Sensor 1 Circuit The purpose is to
Range / Performance detect a stuck coolant Malfunction observe the analog
temperature signal. input signal (KNKS)
from the ATM40
P0117 Engine Coolant The purpose is to device to the micro
Temperature Circuit diagnose the analog controller.
Low Input input signal (TCO)
from the coolant P0335 Crankshaft Position Crankshaft sensor
P0118 Engine Coolant Sensor Circuit diagnosis is based on
Temperature Circuit temperature sensor to
the micro controller. Malfunction valid teeth recognition
High Input procedure. It’s
P0119 Engine Coolant different before / after
Temperature Circuit synchronization.
Intermittent P0340 Camshaft Position Camshaft sensor
P0122 Throttle Position The purpose is to Sensor Circuit signal acquisition
Sensor/Pedal Position diagnose the analog Malfunction is used for engine
Circuit Input Low input signal from the position recognition.
TPS to the micro The polarity of
controller. Camshaft sensor
signal must change
P0123 Throttle Position The purpose is to
only once per
Sensor/Pedal Position diagnose the analog
crankshaft revolution.
Circuit Input High input signal from the
TPS to the micro
controller.
P0130 O2 Sensor Circuit Range of O2 sensor
Malfunction (Bank1 output voltage is
Sensor 1) insufficient.
Continued on next page AP43109,0003246 -19-17SEP12-1/3
40-35-2
Error Code Description Description Error Code Description Description

P0351 Ignition Coil 'A' The purpose of this P0605 Internal Control The purpose of the
Primary Secondary diagnosis function is Module Read Only test is the check
Circuit Malfunction to detect all major Memory (ROM) Error of RAM areas and
P0352 Ignition Coil 'B' failures which can communication
Primary Secondary happen between ECU connections. In the
Circuit Malfunction output and spark stored ECU-failure
plugs, including : bytes, the error
P0353 Ignition Coil 'C' worn out plug (gap location is specified
Primary Secondary of the plug becoming more detailed. Most
Circuit Malfunction too large with age) of the checks are
wiring fault or failure performed during
(connection missing, system start-up.
open...) P0650 Malfunction Indicator The purpose is
P0505 Idle speed actuator The purpose is to Lamp (MIL) Control to diagnose the
command signal diagnose the output Circuit malfunction indicator
incorrect signal from the driver light control signal
P0506 Idle Control System which controls the idle (MIL) from the driver
– RPM lower than air control (IAC). which controls the
expected malfunction indicator
light.
P0507 Idle Control System
– RPM higher than P1166 O2-Sensor –Controller Problem with the
expected Adaptation Diagnosis O2 sensor or circuit.
Malfunction Troubleshoot the
P0560 System Voltage The Main Relay accompanying error
Problem Diagnosis is codes.
performed to detect
if the Main Relay has P1624 Cooling Fan Relay – The purpose is to
switched and remains Circuit Malfunction – diagnose the cooling
on after Key-On and "Low" Circuit fan control signal
if it has switched off P1625 Cooling Fan Relay – from the driver which
after the Power Latch Circuit Malfunction – controls the cooling
Phase. "High" Circuit fan.
P0031 — O2 Sensor Heater Circuit Low Required Tools:

(Bank 1 Sensor 1)
• Multimeter
O2 Sensor Heater Circuit Low (Bank 1 Sensor 1) • service OBD2 ADVISOR
Code Caused By: O2 sensor not heating properly (low) Preliminary Checks:
Engine Performance Effect: Visually ensure that O2 sensor wiring is not compromised
(open or short). If other power related codes are present,
Little to none troubleshoot those first as other conditions may be a factor.
Malfunction Indicator (MIL): Diagnosis
No • Recall, record, and clear codes.
Control Unit Response: • Recreate operating conditions that caused code.
• Recall codes again and check for return of this code.
ECU operates with a default O2 signal value (open loop) • End of tests if code does not return.
until engine is warmed up.
Procedure:
40-35-3
Step 1 Unplug O2 sensor. Turn key switch to run and measure voltage between pins 1 and 3 YES: Go to next step.
[8 Grn (10Hz PWM - low side) and 104G Red wires] on machine side. Does voltage
measure +12Vdc?
NO: Check continuity of
both wires back to ECU
(key switch off).
NO: Check switched power
circuit back through main
harness.
NO: Replace ECU.
Step 2 On sensor side, measure the resistance between Wht wires. Is resistance between 6 YES: If no other codes are
(cold) and 25 (hot) ohms? present, replace ECU.
NO: Replace O2 sensor.
P0032 — O2 Sensor Heater Circuit High Required Tools:

(Bank 1 Sensor 1)
• Multimeter and;
O2 Sensor Heater Circuit High (Bank 1 Sensor 1) • service OBD2
Code Caused By: O2 sensor not heating properly (high) Preliminary Checks:
Engine Performance Effect: Visually ensure that O2 sensor wiring is not compromised.
If other power related codes are present, troubleshoot
Little to none those first as other conditions may be a factor.
No • Recall, record, and clear codes.
ECU operates with a default O2 signal value (open loop) • End of tests if code does not return.
until engine is warmed up.
Procedure:
Step 1 Unplug O2 sensor. Turn key switch to run and measure voltage between pins 1 and 3 YES: Go to next step.
(8 Grn (10Hz PWM - low side) and 104G Red wires on machine side. Does voltage
measure +12Vdc?
both wires back to ECU
(key switch off).
NO: Replace ECU.
Step 2 On sensor side, measure the resistance between Wht wires. Is resistance between 6 YES: If no other codes are
(cold) and 25 (hot) ohms? present, replace ECU.
NO: Replace O2 sensor.
40-35-4
P0107 — Manifold Absolute Pressure Circuit Required Tools:

Low
• Multimeter and;
Manifold Absolute Pressure Circuit Low • service OBD2
Code Caused By: Manifold (TMAP) pressure signal input Preliminary Checks:
low.
Visually ensure that TMAP sensor wiring is not
Engine Performance Effect: compromised. If other power related codes are present,
troubleshoot all codes as other conditions may be a factor.
Reduced output
Diagnosis
Malfunction Indicator (MIL):
• Recall, record, and clear codes.
Yes • Recreate operating conditions that caused code.
Control Unit Response: • Recall codes again and check for return of this code.
• End of tests if code does not return.
Limp home mode
Procedure:
Step 1 Unplug TMAP sensor and turn key switch to run. Measure voltage between pin 4 YES: Go to next step.
and pin 2 [48 Blk/Wht (Gnd) and 46 Blu/Yel (+5Vdc)] on machine side. Does voltage
measure +5Vdc?
NO: Check continuity of 60
Red/Blk (TMAP signal in),
48 B k/Wht (Gnd), and 46
Blu/Yel wires back to ECU
(key switch off).
NO: Go to next step.
Step 2 With key switch off and on machine side, measure resistance between 48 B k/Wht and YES: Test or replace TMAP.
60 Red/Blk wires. Does resistance measure 51.1 ±10% K-ohms?
NO: Replace ECU.
P0108 — Manifold Absolute Pressure Circuit Required Tools:

High
• Multimeter and;
Manifold Absolute Pressure Circuit High • service OBD2
Code Caused By: Manifold (TMAP) pressure signal input Preliminary Checks:
high.
Reduced output
Diagnosis
Yes • Recreate operating conditions that caused code.
Limp home mode
40-35-5
Procedure:
Step 1 Unplug TMAP sensor and turn key switch to run. Measure voltage between pin 4 YES: Go to next step.
and pin 2 [48 Blk/Wht (Gnd) and 46 Blu/Yel (+5Vdc)] on machine side. Does voltage
measure +5Vdc?
Red/Blk (TMAP signal in),
48 B k/Wht (Gnd), and 46
Blu/Yel wires back to ECU
(key switch off).
60 Red/Blk wires. Does resistance measure 51.1 ±10% k-ohms?
NO: Replace ECU.
P0112 — Intake Air Temperature Circuit Low

Required Tools:
Input
• Multimeter and;
Intake Air Temperature Circuit Low Input • service OBD2
Code Caused By: Intake air temperature (IAT) signal Preliminary Checks:
input low.
Difficult starting
Diagnosis
Yes
• Recreate operating conditions that caused code.
n/a
Procedure:
Step 1 Unplug IAT sensor and turn key switch to run. Measure voltage between pin 3 and pin 4 YES: Go to next step.
[48 Blk/Wht (Gnd) and 56 Yel (+5Vdc)] on machine side. Does voltage measure +5Vdc?
48 B k/Wht (Gnd) and 56
Yel wires back to ECU (key
switch off).
60 Red/Blk wires. Does resistance measure 824±10% Ohms?
NO: Replace ECU.
40-35-6
P0113 — Intake Air Temperature Circuit High

Required Tools:
Input
• Multimeter and;
Intake Air Temperature Circuit High Input • Service OBD2
Code Caused By: Intake air temperature (IAT) signal Preliminary Checks:
input high.
Difficult starting
Diagnosis
Yes
n/a
Procedure:
Step 1 Unplug IAT sensor and turn key switch to run. Measure voltage between pin 3 and pin 4 YES: Go to next step.
[48 Blk/Wht (Gnd) and 56 Yel (+5Vdc)] on machine side. Does voltage measure +5Vdc?
48 B k/Wht (Gnd) and 56
Yel wires back to ECU (key
switch off).
60 Red/Blk wires. Does resistance measure 824±10% Ohms?
NO: Replace ECU.
40-35-7
P0116 — Engine Coolant Temperature Circuit codes are present, troubleshoot other codes first as these
Range/Performance Problem conditions may be a driving factor in this DTC.
This DTC differs from other coolant temperature codes
Engine Coolant Temperature Circuit Range/Per- (signal high, low, etc.) by considering these conditions:
formance Problem
Code Caused By: This DTC can have many causes
• Temperature sensor reading is outside of realistic limits.
including malfunctioning IAT, TMAP, and/or knock sensor
• CTS differs from IAT by 17° C (30° F) at start up with a
cold engine after a short period of time.
along with erratic coolant temp sensor readings. • Engine coolant temperature exceeds 107° C (225° F)
Engine Performance Effect: • Coolant temperature sensor failure. This could be
accompanied by codes P0117, P0118, and/or P0119.
Reduced performance • If ECU detects that engine has been running for a
certain amount of time and temperature sensor does
Malfunction Indicator (MIL): not show a small rise in temperature.
Yes
• If no other codes are present, troubleshoot coolant
sensor circuit as follows:
Control Unit Response: Diagnosis
Limp home mode
Required Tools: • Recreate operating conditions that caused code.
• Multimeter and; • End of tests if code does not return.
• Service OBD2
Preliminary Checks:
Visually ensure that coolant temperature (CTS) sensor
wiring is not compromised. If other related malfunction
Procedure:
Step 1 Disconnect coolant temperature sensor connector. With key switch in run position and YES: Test or replace
engine not running, measure voltage between 73 Brn (Gnd) and 31 Blu (Vcc) wires. CTS. See Engine Coolant
Does voltage measure 5Vdc?
Temperature Sensor Test.
NO: With key switch off,
check continuity of both
wires back to ECU.
NO: Poss ble faulty ECU.
40-35-8
P0117 — Engine Coolant Temperature Circuit • Service OBD2

Low Input
Preliminary Checks:
Engine Coolant Temperature Circuit Low Input Visually ensure that coolant temperature sensor (CTS)
sensor wiring is not compromised. If other temperature
Code Caused By: Coolant temperature sensor (CTS)
related codes are present, troubleshoot all codes as other
signal input low beyond normal operating parameters.
conditions may be a factor.
Engine Performance Effect: Code most often caused by faulty CTS or open/grounded
Reduced performance circuit.
Malfunction Indicator Light (MIL): Diagnosis
Yes • Recall, record, and clear codes.

Limp home mode
Required Tools:
• Multimeter and;
Procedure:
Step 1 Disconnect CTS connector. With key switch in run position and engine not running, YES: Test or replace
measure voltage between 73 Brn (Gnd) and 31 Blu (Vcc) wires. Does voltage measure CTS. See Engine Coolant
5Vdc?
Step 2 With key switch off, disconnect connector at ECU. Check for continuity between each YES: Go to next step.
wire at CTS and ECU connectors. Is continuity present?
NO: Repair or replace
wiring harness.
Step 3 Check for continuity between each pin combination at CTS connector. Is continuity YES: Short in wiring.
present? Repair or replace wiring
harness.
NO: Replace ECU.
40-35-9

High Input
Preliminary Checks:
Engine Coolant Temperature Circuit High Input Visually ensure that coolant temperature sensor (CTS)
sensor wiring is not compromised. If other temperature
related codes are present, troubleshoot all codes as other
signal input high beyond normal operating parameters.
Engine Performance Effect: Code most often caused by faulty CTS or open/grounded
Reduced performance circuit.
Malfunction Indicator (MIL): Quick Test: Disconnect CTS connector and place jumper
between 73 Brn (Gnd) and 31 Blu (Vcc) wires. Turn on key
Yes switch. If high temp warning is observed, CTS is faulty.
Control Unit Response: Diagnosis
Limp home mode • Recall, record, and clear codes.

Required Tools: • Recall codes again and check for return of this code.
Procedure:
5Vdc?
wiring harness.
harness.
NO: Replace ECU.
40-35-10

Intermittent
Preliminary Checks:
Engine Coolant Temperature Circuit Intermittent Visually ensure that coolant temperature sensor (CTS)
sensor wiring is not compromised. If other power related
codes are present, troubleshoot all codes as other
signal input high beyond normal operating parameters.
Engine Performance Effect: Code most often caused by faulty wiring or low engine
Reduced performance coolant.

Limp home mode
Required Tools:
• Multimeter and;
Procedure:
5Vdc?
wiring harness.
harness.
NO: Replace ECU.
40-35-11
P0122 — Throttle/Pedal Position Circuit Input • Service OBD2

Low
Preliminary Checks:
Throttle/Pedal Position Circuit Input Low Visually ensure that throttle position sensor (TPS) sensor
wiring is not compromised. If other power related codes
Code Caused By: Throttle position sensor (TPS) input to
are present, troubleshoot all codes as other conditions
ECU is below normal operating parameters.
may be a factor. Look for any physical damage to TPS or
Engine Performance Effect: throttle assembly and linkage.
Reduced performance Diagnosis
Malfunction Indicator (MIL): • Recall, record, and clear codes.

Yes • Recall codes again and check for return of this code.
Control Unit Response:
Limp home model
Required Tools:
• Multimeter and;
Procedure:
Step 1 Disconnect TPS connector. Turn key switch to run with engine not running. Measure YES: Go to next step.
voltage between 38 Blk (Gnd) and 45 Grn/B k (Vcc) wires. Is 5Vdc present?
NO: Turn key switch to off
position. Unplug connector
at ECU and check for
continuity between each of
the TPS and ECU connector
wires (38 Blk, 45 Grn/Blk,
32 Grn/Wht). Repair or
replace as necessary.
NO: Suspect possible
faulty ECU.
Step 2 On TPS, measure resistance between pin 1 [where 32 Grn/Wht wire (signal) would be] YES: Go to next step.
and pin 3 [where 38 Blk wire (gnd) would be]. With throttle fully closed, does resistance
measure 2.1 ±10% K-ohms?
NO: Adjust or repair
throttle body and/or TPS.
Step 3 Repeat above test, only with throttle fully open. Does resistance measure 7.2 ± 10% YES: Faulty ECU.
K-ohms?
NO: Test or replace TPS.
40-35-12
P0123 — Throttle/Pedal Position Circuit Input • Service OBD2

High
Preliminary Checks:
Throttle/Pedal Position Circuit Input High Visually ensure that throttle position sensor (TPS) sensor
wiring is not compromised. If other power related codes
Code Caused By: Throttle position sensor (TPS) input to
ECU is above normal operating parameters.
may be a factor. Look for any physical damage to TPS or
Engine Performance Effect: throttle assembly and linkage.
Reduced performance Diagnosis
Malfunction Indicator (MIL): • Recall, record, and clear codes.

Limp home mode
Required Tools:
• Multimeter and;
Procedure:
Step 1 Disconnect TPS connector. Turn key switch to run with engine not running. Measure YES: Go to next step.
voltage between 38 Blk (Gnd) and 45 Grn/B k (Vcc) wires. Is 5Vdc present?
NO: Turn key switch to off
position. Unplug connector
at ECU and check for
continuity between each of
the TPS and ECU connector
wires (38 Blk, 45 Grn/Blk,
32 Grn/Wht). Repair or
replace as necessary.
NO: Suspect possible
faulty ECU.
Step 2 On TPS, measure resistance between pin 1 [where 32 Grn/Wht wire (signal) would be] YES: Go to next step.
and pin 3 [where 38 Blk wire (gnd) would be]. With throttle fully closed, does resistance
measure 2.1 ±10% K-ohms?
NO: Adjust or repair
throttle body and/or TPS.
Step 3 Repeat above test, only with throttle fully open. Does resistance measure 7.2 ± 10% YES: Faulty ECU.
K-ohms?
NO: Test or replace TPS.
40-35-13
P0131 — O2 Sensor Circuit Low Voltage Required Tools:

(Bank 1 Sensor 1)
• Multimeter and;
O2 Sensor Circuit Low Voltage (Bank 1 Sensor 1) • Service OBD2
Code Caused By: Oxygen sensor input computed by ECU Preliminary Checks:
is consistently approximately 0Vdc.
Visually ensure that oxygen sensor (O2) sensor wiring
Engine Performance Effect: is not compromised. If other air/fuel related codes are
present, troubleshoot all codes as other conditions may
Possible reduced performance. be a factor. Look for any physical damage to O2 sensor.
ECU will record malfunction. It will then enter open loop • End of tests if code does not return.
operation by using a pre-programmed air/fuel mixture
curve based on other sensor inputs.
Procedure:
Step 1 Set multimeter to Vdc. Disconnect O2 sensor connector. Attach multimeter probes to YES: Replace O2 sensor.
O2 sensor connector pin 2 [where 59 Blk wire (O2-) would be] and pin 4 [Where 43
Blu/B k wire (O2+) would be]. Start engine and allow to run during test. Is the voltage
consistently at or near 0Vdc?
NO: Suspect faulty wiring
between ECU and O2
sensor.
NO: Replace O2 sensor. If
problem persists, suspect
faulty ECU.
P0132 — O2 Sensor Circuit High Voltage If this malfunction only appears briefly, and normal O2
(Bank 1 Sensor 1) functionality resumes, it is possible for the ECU to return
to closed loop operation.
O2 Sensor Circuit High Voltage (Bank 1 Sensor 1)
Required Tools:
Code Caused By: Oxygen sensor input computed by ECU
is above 1Vdc. • Multimeter and;
• Service OBD2
Engine Performance Effect:
Preliminary Checks:
Possible reduced performance.
Visually ensure that oxygen sensor (O2) wiring is not
Malfunction Indicator (MIL): compromised. If other air/fuel related codes are present,
Yes
Look for any physical damage to O2 sensor.
Diagnosis
ECU will record malfunction. It will then enter open loop
operation by using a pre-programmed air/fuel mixture • Recall, record, and clear codes.
curve based on other sensor inputs. • Recreate operating conditions that caused code.
40-35-15
Procedure:
AP43109,0003256 -19-19SEP12-2/3
consistently at or near 1Vdc?
between ECU and O2
sensor.
faulty ECU.
P0134 — O2 Sensor No Activity Detected

Required Tools:
(Bank 1 Sensor 1)
• Multimeter and;
O2 Sensor No Activity Detected (Bank 1 Sensor 1) • Service OBD2
Code Caused By: The voltage from the sensor is Preliminary Checks:
consistently approximately 0.3Vdc.
Visually ensure that oxygen sensor (O2) sensor wiring
NOTE: This DTC differs from P0130 (O2 Sensor is not compromised. If other air/fuel related codes are
Malfunction) as output voltage never fluctuates. present, troubleshoot all codes as other conditions may
In the case of P0130, voltage will change be a factor. Look for any physical damage to O2 sensor.
slightly within a certain range.
Diagnosis
Possible reduced performance. • Recreate operating conditions that caused code.
Malfunction Indicator (MIL): • End of tests if code does not return.
Yes
ECU will record malfunction. It will then enter open loop
operation by using a pre-programmed air/fuel mixture
Procedure:
consistently at or near 0.3Vdc?
between ECU and O2
sensor.
faulty ECU.
40-35-16
P0230 — Fuel Pump Circuit Malfunction

Required Tools:
Fuel Pump Circuit Malfunction • Multimeter and;
Code Caused By: The driver from the ECU is above • Service OBD2
approximately 1Vdc. Preliminary Checks:
NOTE: This DTC only deals with the LSD signal from the Visually ensure that fuel pump wiring is not compromised.
ECU. A malfunction with the fuel pump driver from If other fuel related codes are present, troubleshoot all
the relay module will not drive this code. codes as other conditions may be a factor. Look for any
physical damage to fuel pump.
Diagnosis
Possible reduced performance or no run condition.
ECU will record malfunction.
Procedure:
Step 1 With key switch in on position, check voltage at relay module, C-50/J3 pin 3 (fuelpump YES: Check 550 Grn wire,
relay, SN 060001-), 550 Grn wire. Is voltage <1Vdc? C-19 engine connector, and
69 Grn wire back to ECU
for short to ground or open
circuit.
YES: Possible faulty ECU.
Step 2 Is voltage at relay module, C-50/J3 pin 3 (relay, SN 060001-), 550 Grn wire >5Vdc? YES: Check 550 Grn wire,
C-19 engine connector, and
69 Grn wire back to ECU
for short to power or Vcc
sensor signal voltage.
NO: Poss ble faulty ECU.
40-35-17
P0261 - Cylinder 1 — Injector Circuit Low

Required Tools:
Injector Circuit Low • Multimeter and;
Code Caused By: Injector 1 driver is shorted to ground • Service OBD2
or open circuit. Preliminary Checks:
Engine Performance Effect: Visually ensure that injector 1 wiring is not compromised.
If other air/fuel, especially other injector, related codes
Reduced performance
Malfunction Indicator (MIL): may be a factor. Look for any physical damage to injector
connector.
Yes
Diagnosis
ECU will record malfunction. It will then enter oxygen • Recreate operating conditions that caused code.
sensor open loop operation by using a pre-programmed • Recall codes again and check for return of this code.
air/fuel mixture curve based on other sensor inputs. • End of tests if code does not return.
Procedure:
Step 1 With key switch in off position, disconnect connector at injector 1. Check for continuity YES: Repair or replace
to ground at 24 Brn/Grn wire. Is continuity present? wiring harness (indicates
short to ground).
Step 2 Disconnect ECU connector. Check for continuity between 24 Brn/Grn wire at injector 1 YES: Test injector. See
connector and same wire, pin 24 at ECU connector. Is continuity present? Fuel Injector Test.
YES: Suspect faulty ECU.
harness.
P0262 — Cylinder 1 - Injector Circuit High

Required Tools:
Cylinder 1 - Injector Circuit High • Multimeter and;
Code Caused By: Injector 1 driver is shorted to battery • Service OBD2
or overloaded circuit. Preliminary Checks:
Reduced performance
connector.
Yes
Diagnosis
40-35-18
Procedure:
Step 1 NOTE: This DTC is only triggered by the low side driver (LSD) on the injector, but YES: Repair or replace
may be indirectly caused by other injector related faults. wiring harness (indicates
short to power source).
Unplug connector at injector 1. Turn key switch to run. Check for at voltage above NO: Go to next step
approximately 1Vdc at 24 Brn/Grn wire. Is voltage present?
Step 2 Disconnect ECU connector. Check for continuity between 24 Brn/Grn wire at injector 1 YES: Test injector. See
YES: Suspect faulty
injector.
wiring harness (indicates
open circuit).
P0264 — Cylinder 2 - Injector Circuit Low

Required Tools:
Cylinder 2 - Injector Circuit Low • Multimeter and;
Reduced performance
connector.
Yes
Diagnosis
Procedure:
to ground at 61 Brn/Blu wire. Is continuity present? wiring harness (indicates
short to ground).
Step 2 Disconnect ECU connector. Check for continuity between 61 Brn/Blu wire at injector 2 YES: Test injector. See
harness.
40-35-19

Required Tools:
Reduced performance
connector.
Yes
Diagnosis
Procedure:
Unplug connector at injector 2. Turn key switch to run. Check for at voltage above NO: Go to next step
approximately 1Vdc at 61 Brn/Blu wire. Is voltage present?
Step 2 Disconnect ECU connector. Check for continuity between 61 Brn/Blu wire at injector 2 YES: Test injector. See
YES: Suspect faulty
injector.
open circuit).
40-35-20
P0267 — Cylinder 3 - Injector Circuit Low

Required Tools:
Cylinder 3 - Injector Circuit Low • Multimeter and;
Reduced performance
connector.
Yes
Diagnosis
Procedure:
to ground at 23 Brn/Wht wire. Is continuity present? wiring harness (indicates
short to ground).
Step 2 Disconnect ECU connector. Check for continuity between 21 Brn/Wht wire at injector 3 YES: Test injector. See
harness.

Required Tools:
Reduced performance
connector.
Yes
Diagnosis
40-35-21
Procedure:
Unplug connector at injector 3. Turn key switch to run. Check for at voltage above NO: Go to next step.
approximately 1Vdc at 23 Brn/Wht wire. Is voltage present?
Step 2 Disconnect ECU connector. Check for continuity between 23 Brn/Wht wire at injector 3 YES: Test injector. See
YES: Suspect faulty
injector.
open circuit).
P0325 — Knock Sensor 1 Circuit Malfunction

Required Tools:
Knock Sensor 1 Circuit Malfunction • Multimeter and;
Code Caused By: An excessively low or high voltage from • Service OBD2
the knock sensor (KS). Preliminary Checks:
Engine Performance Effect: Visually ensure that KS wiring is not compromised. If
other timing (Crank or cam sensor), related codes are
Possible reduced performance
present, troubleshoot all codes as other conditions may be
Malfunction Indicator (MIL): a factor. Look for any physical damage to KS connector.
Yes Diagnosis
Control Unit Response: • Recall, record, and clear codes.

ECU will record malfunction. It will then enter KS open • Recall codes again and check for return of this code.
loop operation by using a pre-programmed ignition timing • End of tests if code does not return.
Procedure:
Step 1 Turn key switch to off position. Disconnect ECU connector. Check for continuity YES: Go to next step.
between 10 Grn/Red wire at KS connector and same wire, 10 Grn/Red wire (pin 10) at
ECU connector. Is continuity present?
harness.
Step 2 Check for continuity between 54 Pur/Wht wire at KS and 54 Pur/Wht wire (pin 54) at YES: Test KS. See Knock
ECU connector. Is continuity present? Sensor Test.
YES: If KS is ok, suspect
faulty ECU.
wiring.
40-35-22
P0335 — Crankshaft Position Sensor Required Tools:

Malfunction
• Multimeter and;
Crankshaft Position Sensor Malfunction • Service OBD2
Code Caused By: A problem with the crankshaft position Preliminary Checks:
sensor (CKP) or associated circuit.
Visually ensure that CKP wiring is not compromised.
Engine Performance Effect: If other timing (Camshaft sensor), related codes are
present, troubleshoot all codes as other conditions may be
Possible reduced performance or no run condition. a factor. Look for any physical damage to CKP connector.
ECU will record malfunction. ECU will attempt to run • End of tests if code does not return.
engine by using timing pulses from crankshaft sensor
(CKP).
Procedure:
Step 1 With key switch in on position, unplug connector at CKP. Check for battery voltage YES: Go to next step.
at 104F Red wire. Is +12Vdc present?
short to ground or open
circuit).
Step 2 NOTE: ECU has its own internal ground for sensors. ECU ground may “float” up to 1Vdc YES: Go to next step.
over frame ground. Most accurate measurements are made using sensor ground.
Is there continuity between 27 Brn/B k wire and ground? NO: Turn key switch off.
Check continuity between
CKP and ECU connector
(disconnected) on 27
Brn/Blk wire.
Step 3 With key switch in run position, is approximately 5Vdc present at CKP sensor connector YES: Test CKP sensor by
29 Blu/Grn wire? substitution.
YES: Possible flywheel
and/or timing problem. See
Engine section.
29 Blu/Grn wire to ECU
connector.
40-35-23
P0340 — Camshaft Position Sensor Required Tools:

Malfunction
• Multimeter and;
Camshaft Position Sensor Malfunction • Service OBD2
Code Caused By: A problem with the camshaft position Preliminary Checks:
sensor (CMP) or associated circuit.
Visually ensure that CMP wiring is not compromised. If
Engine Performance Effect: other timing (Crank sensor), related codes are present,
Possible reduced performance or no run condition. Look for any physical damage to CMP connector.
engine by using timing pulses from crankshaft sensor
(CKP).
Procedure:
Step 1 With key switch in on position, disconnect connector at CMP. Check for battery voltage YES: Go to next step.
at 104E Red wire. Is +12Vdc present?
circuit).
Step 2 NOTE: ECU has its own internal ground for sensors. ECU ground may “float” up to 1Vdc YES: Go to next step.
over frame ground. Most accurate measurements are made using sensor ground.
Is there continuity between 30 Grn/Org wire and ground? NO: Turn key switch off.
CMP and ECU connector
(disconnected) on 30
Grn/Org wire.
Step 3 With key switch in run position, is approximately 5Vdc present at CMP sensor connector YES: Test CMP sensor by
72 Pnk wire? substitution.
YES: Possible camshaft
and/or timing problem. See
Engine section.
Pnk wire to ECU connector.
40-35-24
P0351 — Ignition Coil ‘A’ Primary Secondary Required Tools:

Circuit Malfunction
• Multimeter and;
Ignition Coil ‘A’ Primary Secondary Circuit Malfunction • Service OBD2
Code Caused By: A problem with ignition coil ‘A’ (1) or Preliminary Checks:
associated circuit. Incorrect current reading.
Visually ensure that ignition wiring is not compromised. If
Engine Performance Effect: other ignition coil related codes are present, troubleshoot
all codes as other conditions may be a factor. Look for
Possible reduced performance or poor run condition. any physical damage to coil connector, spark plug wire,
and spark plug,.
Diagnosis
Yes
ECU will record malfunction. ECU will attempt to run • Recall codes again and check for return of this code.
engine using remaining ignition coils. • End of tests if code does not return.
Procedure:
Step 1 With key switch in on position, disconnect connector at ignition coil. Check for battery YES: Go to next step.
voltage at 103C Org wire. Is +12Vdc present?
circuit).
Step 2 NOTE: ECU has its own internal ground for ignition coils. ECU ground YES: Go to next step.
may “float” up to 1Vdc over frame ground. Most accurate measure-
ments are made using coil ground.
Is there continuity between 34 Brn/Yel wire and ground? NO: Turn key switch off.
ignition coil and ECU
connector (disconnected)
on 4 Brn/Yel wire.
Step 3 Test ignition coil. Is coil ok? See Ignition Coil Test. YES: Go to next step.
NO: Replace coil.
Step 4 Test spark plug wire. Is wire ok? YES: Go to next step.
NO: Replace wire.
Step 5 Test spark plug. Is plug ok? YES: Faulty ECU.

NO: Replace spark plug.
40-35-25
P0352 — Ignition Coil ‘B’ Primary Secondary Required Tools:

Circuit Malfunction
• Multimeter and;
Ignition Coil ‘B’ Primary Secondary Circuit Malfunction • Service OBD2
Code Caused By: A problem with ignition coil ‘B’ (2) or Preliminary Checks:
and spark plug.
Diagnosis
Yes
Procedure:
voltage at 103B Org wire. Is +12Vdc present?
circuit).
Is there continuity between 5 Blu/Grn wire and ground? NO: Turn key switch off.
on 5 Blu/Grn wire.
NO: Replace coil.
NO: Replace wire.

40-35-26
P0353 — Ignition Coil ‘C’ Primary Secondary Required Tools:

Circuit Malfunction
• Multimeter and;
Ignition Coil ‘C’ Primary Secondary Circuit Malfunction • Service OBD2
Code Caused By: A problem with ignition coil ‘C’ (3) or Preliminary Checks:
and spark plug.
Diagnosis
Yes
Procedure:
voltage at 103A Org wire. Is +12Vdc present?
circuit).
Is there continuity between 3 Grn wire and ground? NO: Turn key switch off.
on 3 Grn wire.
NO: Replace coil.
NO: Replace wire.

40-35-27
P0505 — Idle Speed Actuator Command Required Tools:

Signal Incorrect
• Multimeter and;
Idle Speed Actuator Command Signal Incorrect • Service OBD2
Code Caused By: A problem with the idle air control circuit Preliminary Checks:
(IAC) or engine vacuum leak.
Visually ensure that IAC wiring is not compromised. If
Engine Performance Effect: other IAC related codes are present, troubleshoot all
codes as other conditions may be a factor. Look for any
Possible reduced performance or poor run condition. physical damage to IAC connector, dirty air filter or throttle
Possible stalling of engine at idle. body, bad PVC valve, or vacuum leaks.
engine.
Procedure:
Step 1 With key switch in on position, unplug connector at IAC. Check for battery voltage YES: Go to next step.
between 35 Grn and 36 Blu/Red wires. Is +12Vdc present?
NO: Turn key switch off.
IAC and ECU connector
(unplugged) on 35 Grn and
36 Blu/Red wires.
Step 2 NOTE: ECU has its own internal ground for IAC. ECU ground may “float” up to 1Vdc YES: Go to next step.
over frame ground. Most accurate measurements are made using IAC ground.
Check for battery voltage between 19 Blu and 20 Wht wires. Is +12Vdc present? NO: Turn key switch off.
(unplugged) on 19 Blu and
20 Wht wires.
Step 3 Does IAC pass “Idle Air Control Test”? YES: Possible faulty ECU.
YES: See engine
diagnostics in Engine
section.
NO: Replace IAC.
40-35-28
P0506 — Idle Air Control System - RPM Required Tools:

Lower Than Expected
• Multimeter and;
Idle Air Control System - RPM Lower Than Expected • Service OBD2
Code Caused By: A problem with the idle air control (IAC) Preliminary Checks:
or engine mechanical problem.
Possible reduced performance or poor run condition. physical damage to IAC connector, dirty air filter or throttle
Possible stalling of engine at idle. body, bad PCV valve, exhaust restriction, or vacuum leaks.
engine.
Procedure:
36 Blu/Red wires.
20 Wht wires.
YES: See engine
section.
NO: Replace IAC.
40-35-29
P0507 — Idle Air Control System - RPM Required Tools:

Higher Than Expected
• Multimeter and;
Idle Air Control System - RPM Higher Than Expected • Service OBD2
Code Caused By: A problem with the idle air control (IAC) Preliminary Checks:
or engine mechanical problem.
Possible reduced performance or poor run condition. physical damage to IAC connector, damaged or dirty
throttle body, bad PCV valve, or intake manifold leaks.
Diagnosis
Yes
engine. • End of tests if code does not return.
Procedure:
36 Blu/Red wires.
20 Wht wires.
YES: See engine
section.
NO: Replace IAC.
40-35-30
Step 2 NOTE: ECU has its own internal ground. ECU ground may “float” up to 1Vdc over YES: Ensure that there is
frame ground. Most accurate measurements are made using ECU ground. continuity to frame ground
at ECU connector 1 and 2
Blk wires (pins 1 and 2). If
not, check ground circuit.
Disconnect connector at ECU. Turn key switch to on. Measure voltage at 63 Gry/Red YES: Possible faulty ECU.
wire (pin 63) and 44 Gry/Red wire (pin 44). Is battery voltage present at both pins?
YES: Go to next step.
NO: If battery voltage
is present at only one of
the wires, check for bad
circuit wiring back to engine
connector.
NO: If both wires have no
power. test power circuit.
P0605 — Internal Control Module Read Only

Required Tools:
Memory (ROM) Error
• Multimeter and;
Internal Control Module Read Only Memory (ROM) Error • Service OBD2
Code Caused By: Controller internal software Preliminary Checks:
malfunctioning. Possible causes:
This code may be accompanied by other malfunctions or
• ECU internal calculation malfunction DTCs. If any other malfunctions are present, they may aid
• Corrupt ROM software in diagnosing problem before proceeding further.
• ECU auto shutoff malfunctioning
• Incorrect payload installed NOTE: Ensure that correct payload and/or ECU
• Electromagnetic interference (EMI) from external is installed on machine.
sources
Visually ensure that ECU wiring is not compromised. If
Engine Performance Effect: other ECU related codes are present, troubleshoot all
Possible reduced performance or no run condition. physical damage to ECU connector.
No response to no run condition. • End of tests if code does not return.
Procedure:
Step 1 Have all of the previous potential causes for malfunction been checked and eliminated? YES: Check DTAC cases
for known issues/fixes.
YES: Replace ECU.
NO: Reinstall correct
payload.
NO: Check listed causes
for DTC.
40-35-32
P1166 — O2 Sensor - Controller Adaptation • Service OBD2
Diagnosis Malfunction
Preliminary Checks:
Controller Adaptation Diagnosis Malfunction If this code is accompanied by DTC P0031 (O2 sensor
heater circuit low) or P0032 (O2 sensor heater circuit
Code Caused By: A problem with the O2 sensor or circuit.
high), follow those troubleshooting procedures.
Engine Performance Effect: If this code is accompanied by the following, troubleshoot
Possible reduced performance or poor run condition. these codes first:
Malfunction Indicator (MIL): • P0130

• P0131
Yes • P0132
• P0134
Diagnosis
ECU will record malfunction. ECU will attempt to run
engine. • Recall, record, and clear codes.
Required Tools: • Recall codes again and check for return of this code.
40-35-34
Procedure:
Step 1 Replace O2 sensor. Does code clear? YES: End of tests.

NO: Suspect faulty ECU.
P1624 — Cooling Fan Relay - Circuit

Preliminary Checks:
Malfunction - “Low” Circuit
NOTE: This circuit is for cooling fan relay control operation.
Cooling Fan Relay - Circuit Malfunction - “Low” Circuit It should not be confused with P1625 “Cooling fan
relay - circuit malfunction - ‘High’ circuit”. The latter
Code Caused By: A problem with the cooling fan relay is for display panel temperature indicator light.
(Lo circuit).
This code is only associated with input type cooling
Engine Performance Effect: DTCs if the fan control relay is affected.
Possible reduced performance or poor run condition.
Operation of this circuit and DTC is best understood
Malfunction Indicator (MIL): by reviewing cooling fan circuit operation. See Coolant
Temperature Sensor Circuit Operation.
Yes
Ensure that no other codes are present when
Control Unit Response: troubleshooting this DTC. This circuit relies on proper
operation of ECU and relay module (fan relay, SN
ECU will record malfunction. ECU will attempt to run 060001-) to properly diagnose.
engine.
Diagnosis
Required Tools:
• Multimeter and; • Recreate operating conditions that caused code.
• Service OBD2 • Recall codes again and check for return of this code.
Procedure:
Step 1 IMPORTANT: Avoid Damage! Never connect or disconnect a any control YES: Go to next step.
module connector with power applied.
With key switch off, disconnect C-50/J3 at relay module (fan relay, and J1 at ECU. NO: Check wires and
Is continuity present between J1 65 Org wire (pin 65) and C-50/J3 310 Org wire engine connector. Repair or
(pin 1)? replace as needed.
Step 2 Test conditions:

• Connect both removed connectors
• Disconnect connector at temperature sensor.
• Place a jumper between 73 Brn wire (pin C) and 31 Blu wire (pin A) on harness side.
• Turn key switch to run. YES: Go to next step.
Does fan run? NO: Most likely problem
with relay module/fuses
(relay, SN 060001-).
40-35-35
Step 3 Probe rear of relay module, C-50/J3 310 Org wire, pin 1 (fan relay, SN 060001-). Is YES: Go to next step.
1.5VDC to 0Vdc present?
NO: Suspect failed ECU.
Step 4 Remove jumper from temperature sensor connector. Does battery voltage climb YES: Circuit is functioning.
to battery voltage and fan stop? Poss ble erroneous DTC.
NO: Suspect failed ECU.
P1625 — Cooling Fan Relay - Circuit “Cooling fan relay - circuit malfunction - ‘Low’
Malfunction - “High” Circuit circuit”. The latter is for cooling fan control.
This code is not associated with LCD coolant
Cooling Fan Relay - Circuit Malfunction - “High” Circuit temperature display.
Code Caused By: A problem with the coolant temperature This code is only associated with input type cooling
light (Hi circuit) DTCs if the coolant light is affected.
Operation of this circuit and DTC is best understood by
Limp home mode reviewing “Coolant Temperature Sensor Circuit Operation”.
Malfunction Indicator (MIL): Ensure that no other codes are present when
troubleshooting this DTC. This circuit relies on proper
Yes operation of ECU and display panel to properly diagnose.
Control Unit Response: Perform power on self test (POST) by turning key switch
to run position and observe display panel. Under normal
ECU will record malfunction. ECU will attempt to run circumstances, coolant light should illuminate briefly and
engine. then go out. If light passes POST, suspect intermittent
problem under field conditions.
Required Tools:
Diagnosis
• Multimeter and;
• Service OBD2 • Recall, record, and clear codes.
Preliminary Checks: • Recreate operating conditions that caused code.
NOTE: This circuit is for coolant temperature light control • End of tests if code does not return.
operation. It should not be confused with P1624
40-35-36
Power Circuit Operation 12 Volt DC tie point for the alternator output wire. Two
fusible links at the positive battery terminal oversee all
Function: other circuits.
To provide unswitched and switched power to the primary The battery cables and the starting motor tie point
electrical components whenever the battery is properly connections must be clean and secure in order for the
connected. machine electrical system to work properly. The ground
The power circuits are divided among the unswitched cables and connections are equally as important. Proper
power circuit, switched power circuits (key switch in run starting motor operation depends on these cables and
position), and secondary power circuits. The secondary connections to carry high current.
power circuits become energized when switched power Switched Power:
circuits energize relays and/or control modules, providing
current paths to the secondary circuits. The secondary In addition to the voltage present at the unswitched
power circuits will not be energized if the component power circuits, it must also be present at the following
managing the current path(s) fails to receive the required components or connectors with the key switch in the run
signals or should otherwise become defective. position:
NOTE: The following description only encompasses • Key switch S3 (A)
the components that should always have power • Fuse for lighting on load center (both sides) C-60
with the key switch on. Many other components • A1 Relay module C-50 (J1), pin 3
will likely have power, but that is dependent • Fuses F12 and F7
on operating conditions. • Display panel C-26 (J1)
• Brake switch C-32
Unswitched Power: • Park brake switch
Voltage must be present at each of the following • Reverse switch S20
components or connectors with the key switch in the off • Alternator
position:
• Fuel Pump Relay
• Battery positive terminal
• Start motor BAT terminal
• All fuses
• Fuel Pump Relay
• Start Relay
• Fan Relay
• Power Port connector
• Relay module
• Diagnostics Connector
• Alternator

Unswitched Power (Main)

40-40-2
• Battery Is battery voltage present at battery positive (+) terminal?
• Key switch in OFF position

• Meter negative lead (—) on battery negative (—) terminal or frame ground
• Check connections for corrosion or looseness when testing YES: Go to next step.
• Ensure that ground connections are secure and that there is continuity to the battery NO: Charge or replace
negative (—) post. battery.
• If diagnosis fails to correct problem, use Service OBD2, or find relevant OBD NO: If using frame ground,
diagnostics in this manual, or see your dealer. check ground circuits.
• Start Solenoid Is battery voltage present at start solenoid, 81A Red wire? YES: Go to next step.
NO: Check 81A Red wire

and connections.
• Alternator Is battery voltage present at G2 alternator, 81B Red wire? YES: Go to next step.
NO: Check 81B Red wire

and connections.
• Load Center At load center, is battery voltage present on both sides of 20A, 5A and 3A fuses? YES: Go to next step.
NO: Test fuses.

NO: Check 201 fuse link,
205 Red wire, S-12 splice,
and respective wires:
• Key Switch Is battery voltage present at key switch, 208 Red wire? YES: Go to next step.
NO: Check 208 red wire.
• Display Panel Is battery voltage present at at display panel 508 Red wire, J1/pin C (Batt+)? YES: Go to next step.
NO: Check 508 Red wire.
• Engine Connector Disconnect main harness to engine connector. Is battery voltage present at 226 Red
wire?
YES: Go to next step, or
use Service OBD2 to
diagnose if problems
continue.
40-40-3
• Fuse Is battery voltage present on both sides of C-32 40A fuse? YES: Go to next step.
NO: Test 40A fuse.

NO: Check 205K Red wire
and connections.
• Power Connector Is battery voltage present at C-6 front power connector, 203 Red wire? YES: Go to next step.
• Fuse Is battery voltage present on both sides of C-33 40A fuse? YES: Go to next step.
NO: Test fuse.
• Rear Power Connector Is battery voltage present at C-10 rear power connector, 204 Red wire? YES: Go to next step.
NO: Check 204 Red wire

and connections.
• Fuel Pump Relay Is battery voltage present at K01 fuel pump relay 556 Red wire? YES: Continued
NO: Check 205W Red

wire, 10A fuse, 556 Red
wire and connection
• Start Relay Is battery voltage present at K02 start relay 253 Red wire? YES: Go to next step.
NO: Check 205C Red wire,

20A fuse, 253 Red wire and
connections.
• Fan Relay Is battery voltage present at K03 fan relay 205Z Red wire? YES: Go to next step.
NO: Check 205Z Red wire

and connections.
40-40-4
• Fan Relay Is battery voltage present at K03 fan relay 252 Org wire? YES: Go to next step.
NO: Check 205L wire, 30A

fuse, 252 Org wire and
connections.
• Front Power Port Is battery voltage present at C-38 front power port, 207 Red wire? YES: End of main
unswitched power circuit
tests.
NO: Check 205E Red wire,
10A fuse, 207 Red wire and
connections.
Switched Power
• Key Switch Is battery voltage present at S3 key switch, 420J and 420Z Yel wires (spliced)?
• Key switch in ON position.

• Relevant unswitched power circuits checked.
• Meter negative lead (-) on battery negative (-) terminal or frame ground
• Check connections for corrosion or looseness when testing.
• Ensure that ground connections are secure and that there is continuity to the battery YES: Go to next step.
negative (-) post.
• If diagnosis fails to correct problem, use Service OBD2, or find relevant OBD NO: Test key switch.
diagnostics in this manual, or see your dealer.
40-40-5
Cranking Circuit Operation Moving the key switch to the crank position then allows
Function: power to flow over the 705C Pur wire to the K02 start
relay coil.
To energize the starting motor solenoid and engage the
starting motor to crank the engine.
Operating Conditions: This enables the start relay to close its contacts and supply
battery power over the 700 Pur/A44 Pur wires to the
• Key switch in start position starting motor solenoid. The starting motor solenoid can
• Transmission in neutral now close the solenoid contacts, permitting high current
Theory of Operation: from the battery to pass through to the starting motor. The
starting motor engages the flywheel and cranks the engine.
The only safety-related required for cranking
circuit operating is that the transmission be placed in the
neutral position.
253 Red
420D Yel
S12
D1 D2 Neutral Engaged
20A
Switch Neutral
D4 D3 208 Red 420T Yel
20A
S-2
101Z Blk
T-12 S3
205C Red
205A Red
Ground Key
C-50 / J1 Switch
Off
Ground 1 Run
Start
Key “ON” Power 3 710 Pur
711 Pur S2 S1 705C Pur
S-12 Neutral Switch Input 4
208 Red B A 420J Yel
Speed Sensor Input 7
G M
Seat Belt Input 8
Park Brake Buzzer 9
205 Red
Speed Sensor Out 10

Extra Relay Drive Sink 11
4WD Switch Input 12
Load Shed 13
705 Pur
Key Switch Crank 14
4WD Solenoid Driver 15
K02
202 Red to S-1 Start
S-6 A B+
A1 Relay Ground
B Glow Plugs
Module Relay
C V_EL
D Ignition Coil Supply C-19
201
86
85
100X Blk
A4 B6
C-8 / J3
87
81A Red A44 Pur 1 H 700 Pur 253 Red

A6 B4
30
Start Solenoid
+ 87a
G1 B A
Battery
- Y1
100 Blk
M
Start
T-7 Motor
Frame
Ground
Cranking Circuit Schematic (SN 060001-)
40-40-8
A1—Relay Module S3— Key Switch
K02— Start Relay S12— Neutral Switch
40-40-9
G2 C-19 Engine
Alternator Connector
082 Wht 610 Brn
81B Red G » Pin 3/F
3 A17 Red/Wht 422X Yel
U » Pin 9/J C-25 / J2
Seat Belt A
Engine Diag B
S3 Park Brake C
Key Glow Plug D
Off Switch A2 4WD Drive E
Run F Left Turn F
Start Display
Right Turn G
Panel
Neutral H
S2 S1
Reverse J
Low K
208 Red B A 420J Yel
20A S-2 High L
D4 D3
Park M
G M
420M Yel
5A Battery Discharge N
C7 C8
Coolant Switch P
Spare R
205A Red
205Y Red
Not Used S
81B Red
A Key Power +
B Fuel Sender
508 Red
C Batt +
D Ambient Air Temp (not used)
S-12 E Coolant Sensor
102E Blk
F Battery -
G Oil Pressure
205 Red
H Tachometer (freq in)

J Speed Sensor (freq in)
K Model Select (VBAT = diesel)
T-12
S-6 Ground C-26 / J1
201
81A Red
CT-6
B S +
G1
Battery
-
M
Start
100 Blk
Motor
T-7
Frame
Ground
A2—Display Panel G1—Battery S3— Key Switch

C-19— Engine Connector G2—Alternator
Charging Circuit Diagnosis
Charging Circuit Diagnosis

40-40-11
Tachometer Circuit Operation The tachometer receives its signal from the engine speed
Function out (ESS) signal generated from the ECU (pin 66) to the
C-19 connector, pin R/15, 66 Yel wire. The 500 Blu wire
To indicate engine speed in rpm to the operator. carries this signal to the display panel, C-26/J1 pin H.
This signal consists of a series of pulses generated by
the engine’s camshaft sensor. The display panel will then
• Key switch in run position count and time the pulses, interpret them, and output a
• Engine running rpm figure on the LCD.
508 Red
420M Yel
S3
Off
Key
Run Switch
Start
C7 C8 S2 S1
5A
D4 D3 208 Red B A 420J Yel
20A S-2
G M
205Y Red
205A Red
C-50 / J1
101Z Blk
Ground 1
420D Yel
S-12 Neutral Switch Input 4
875E Pnk
Speed Sensor Input 7 C-98
Seat Belt Input 8 EPAS
Park Brake Buzzer 9
205 Red
Speed Sensor Out 10 D

875 Pnk
Extra Relay Drive Sink 11 C
890 Blk
4WD Switch Input 12 B
Load Shed 13 A
Key Switch Crank 14 B30
4WD Solenoid Driver 15 Speed
100Y Blk
202 Red
Sensor
S-6 A B+
A1 Relay
875C Pnk
B Glow Plugs
Module
C V_EL
D Ignition Coil Supply
T-12
201
Ground
C-8 / J3
+
G1
Battery
- 875C Pnk
100 Blk
T-7
Frame
Ground
Hour/Speed/Tach Schematic 1 of 2
A1—Relay Module B30— Speed Sensor G1—Battery
S3— Key Switch
40-40-17
508 Red
S3
Off
Key
Run Switch
C7 C8 Start
5A
D4 D3 208 Red S2 S1
20A
101Z Blk B A 420J Yel
T-12
205Y Red
205A Red
Ground G M
C-50 / J1
Ground 1
420D Yel S-2 420M Yel
S-12 Neutral Switch Input 4 S4
Throttle Switch Input 5 Seat Belt
Off
Seat Belt Lamp Driver 6 Switch
Speed Sensor Input 7 On
684 Grn 420E Yel
Seat Belt Input 8
Park Brake Buzzer 9
205 Red
Speed Sensor Out 10

Extra Relay Drive Sink 11 C-25 / J2
4WD Switch Input 12
961 Wht
Load Shed 13 A Seat Belt
Key Switch Crank 14 B Engine Diag
4WD Solenoid Driver 15 C Park Brake
D Glow Plug
202 Red
S-6 A B+
A1 Relay E 4WD Drive
B Glow Plugs F Left Turn A2
Module Display
C V_EL G Right Turn
D Ignition Coil Supply H Neutral Panel
201
J Reverse
C-8 / J3 K Low
L High
508 Red
420M Yel
M Park
+
N Battery Discharge
G1 P Coolant Switch
Battery R Spare
-
S Not Used
Key Power + A
100 Blk
Fuel Sender B
T-7 Batt + C
Frame Ambient Air Temp (not used) D
Ground Coolant Sensor E
102E Blk
Battery - F
Oil Pressure G
Tachometer (freq in) H
Speed Sensor (freq in) J
Model Select (VBAT = diesel) K
T-12
C-26 / J1 Ground
A1—Relay Module G1—Battery S4— Seat Belt Switch

A2—Display Panel S3— Key Switch
40-40-20
• Throttle Switch
Connector
Is battery voltage present at C-44 throttle switch, 811 Pnk wire? YES: Go to next step.
NO: Check 811 Pnk circuit

between park brake switch
and throttle switch.
• Continued Is battery voltage present at throttle switch 1005 Pur wire? YES: Go to next procedure.
NO: Test throttle switch.
• Relay Module Is battery voltage present at A1 relay module, J1/ pin 5, 105 Pur wire? YES: Suspect fauly relay
module if buzzer and park
brake circuits are ok.
NO: Check 105 Pur wire
and connections.
40-40-26
Cooling Circuit Operation Theory of Operation - Coolant Temperature Light:

Function: When the ECU senses that the coolant temperature
To provide an input to the electronic control unit to process exceeds 115ºC (239ºF), it sends a LO signal to the display
and supply the appropriate outputs to manage the radiator panel via the 64 Org and 305 Pnk wires. This signal
fan, engine coolant temperature warning light, and the allows the display panel to illuminate and flash the coolant
fuel system. Also provides a signal to the display panel’s temperature warning light.
temperature gauge. The temperature warning light continues stay on until the
Theory of Operation - Coolant Temperature Sensor: engine temperature drops below 110ºC (230ºF).
The coolant temperature sensor contains two thermistors. NOTE: Whenever the light is illuminated, the ECU will
A thermistor is a semiconductor device having a resistance go into “limp home mode” to protect the engine.
that decreases rapidly with an increase in temperature. Reduced performance will result.
One thermistor is used exclusively by the ECU to control Theory of Operation - Temperature Gauge:
the cooling fan, engine operation, and the coolant
temperature warning light. The remaining thermistor is The temperature gauge is an LCD bar graph display that
connected to the display panel temperature gauge. receives an analog signal from the temperature sensor
via the 090 Red and 300 Org wires. This circuit works
Although physically housed in the same sensor, the two independently from fan and temperature light operation.
thermistors are electrically isolated.
The variable resistance from the coolant temperature
Theory of Operation - Cooling Fan: sensor is processed within the display panel by an
analog-to-digital (A/D) converter. The resultant digital
As the coolant temperature approaches 95°C (203ºF),
signal is then used to operate the temperature gauge bar
the ECU sends a ground level (“LO”) signal via the 65
graph.
and 310 Org wires to the K03 fan relay fan switch input.
One side of the fan relay coil has switched battery voltage Schematic Components
(V_EL) with the key switch on. The LO signal grounds
the opposite end of the coil, energizing the relay. Battery A1 — Relay Module
power from the 30A fan fuse flows via the relay contacts A2 — Display Panel
and 315 Org wire to the C-22 cooling fan connector. A3 — ECU
The fan motor is grounded by the 100A Blk wire to the C-19 — Engine Connector
100-series ground bus. K03 — Fan Relay
M22 — Fan Motor
Cooling fan operation continues until the engine S3 — Key Switch
temperature drops below 88ºC (190ºF).
40-40-28
Electronic Controller Power Flow Operation engine wire harness 22 Yel wires to the A3 ECU [J1, pin
22 (V_IG)]. The ECU will then perform a Power On Self
Test (POST).
Function:
If the POST is successful, the ECU will send a 12Vdc
To describe how controller’s power circuits interact with signal out at J1, pin 67. The 67 Grn and 669 Brn wire
one another for proper machine operation. will input this voltage at the A1 relay module C-50/J1,
Operating Conditions: pin 2. This tells the relay module that the ECU is ready.
The relay module will then close its internal contacts on
• Key switch in on position. the main relay and send power back to the ECU out of
C-8/J3, pin B (V_EL). This travels over the 699, 104 and
Theory of Operation: 21 Red wires to ECU J1, pin 21. The V_EL power input is
The A1 relay module and A3 Engine Control Unit (ECU) required for the ECU to operate and accept signal input
perform a “handshake” operation before the machine will and provide output to machine components.
function. The display panel only serves to potentially If either controller fails its POST, the machine will not
display an error if this operation is not successful. run and an error indicator may or not be present on the
Unswitched power is always supplied to the relay module display panel.
via the 202 Red wire (C-8/J3, pin A). Unswitched power The display panel will receive unswitched power (C-26,
is sent to the ECU over the 226 Red wire to the engine J1, pin C) via the 508 Red wire, and switched power over
wire harness 44 and 63 Gry/Red wires (J1, pins 44 and 420x Yel series wires (C-26, J-1, pin A). The only function
63 respectively). This same power is sent out to the key of the display panel in power up operation is to display an
switch via the 208 Red wire. error if present.
With the key switch in the on position, power exits the IMPORTANT: Avoid Damage! Troubleshooting
key switch over the 420J and 420D Yel wires (C-50/J3, controllers requires Service OBD2 and/or on-
pin 7) to the A1 relay module. The relay module will then board diagnostics. Except as stated in Power
perform a Power On Self Test (POST). Circuit Diagnostics, permanent damage can
At the same time power exits the key switch over the occur to controllers without using OBD
420J and 422X Yel wires to the engine connector and diagnostic procedures.
40-40-40
45
Operation and Diagnostics - Electronic Controllers
Troubleshooting Electronic Controllers

Problems Due to Intermittent Electrical Failures:
NOTE: This reference is a guideline for troubleshooting NOTE: Electrical intermittent failures are
problems that still exist after standard diagnostics usually caused by harness, terminal or
have been performed. These problems are connector problems.
typically due to specific operating conditions,
intermittent failures or, in rare cases, control unit • Inspect all connectors and terminals of related circuits.
failures. Depending on the situation, some or all • Inspect mechanical linkages for interference with
of the following may be important. harnesses or connectors.
• Inspect harnesses for missing or improperly installed
Problems Due to Specific Operating Conditions: clamps or bands. Loose harnesses that are allowed to
move too freely or harnesses that are banded too tightly
Review all recorded codes and consult with operator may result in worn or damaged wires.
to determine operating and vehicle conditions when the • Inspect mechanical linkages for proper operating
problem occurs. Record details. condition.
• Does code/problem occur at the same time as other Problems Due to Control Unit Failures:
problems?
• Does code/problem occur when vehicle is warm or cold? NOTE: Before replacing control unit, review all tests.
• Does code/problem occur during field or transport Control units are the least likely cause of failure!
operation?
• Does code/problem occur while performing a specific • If all checks have been made with no problems identified,
action such as shifting, turning, braking, operating check power and ground circuits. Power inputs must be
certain hydraulics? within 1 V of battery voltage and ground circuits must
• When did code/problem first appear? Was there any be less than 1.0 ohm to the vehicle single point ground.
maintenance performed recently? (If yes, inspect areas • Do not confuse low side driver (LSD) or dedicated
of maintenance for inadvertent damage or improper sensor/control grounds with frame ground. These
installations.) grounds or LSDs are often at a higher potential than
frame ground.
Attempt to recreate code/problem based on conditions. If • Inspect all connectors and terminals of associated
possible, repeat operational, system, electrical, hydraulic control units.
or mechanical checks under these conditions.
40-45-1
On Board Diagnostics - ECU • B = Body

Diagnostic Trouble Codes (DTCs):
• C = Chassis
• U = Unspecified
The ECU is capable of recording current or stored DTCs 2nd Digit:
to its memory. If a malfunction exists, ti will turn on
the malfunction indicator light (MIL). This light will only • 0 = Standard
indicate that a problems exists, not display what the • 1 = Manufacturer Specific
specific problem is. In order to display the specific DTC(s),
3rd Digit:
Service OBD2 must be connected to the machine.
An industry standard ISO 9141-2 serial communication • 1 = Emission Management
protocol is used for DTC retrieval. • 2 = Injector Circuit
• 3 = Ignition
Description of Code Structure: • 4 = Auxiliary Emission
• 5 = Vehicle Speed & Idle Control
Sample Code: P0031 • 6 = Computer and Output Circuit
Code digit position - 1 2 3 4 5
• 7 = Transmission
The remaining digits describe the specific malfunction
1st Digit: which may or may not be industry standards.
• P = Powertrain
40-45-2
Electronic Control Module/Relay Module When operating conditions have been met, the ECM
(ECM) Operation distributes power to various components depending
Function: upon operator preference, ECU commands, or operating
conditions.
Provides fused power distribution to various components
as well as processing certain inputs and outputs for Also, either directly or indirectly (ECU command), the
discrete components and the ECU. ECM controls these functions:
The ECM does not have a driver to cause the malfunction • Ignition coil supply
but has components andcircuitry that may cause the • ECU power
ECU to turn on the MIL. Itdoes have its own diagnostic • Cooling fan
light and functions though. • Start motor
• Key in run or start position,
• Engine running.
Theory of Operation: With the exception of fuse replacement, the ECM is not
Power is supplied to the electronic control module (ECM) serviceable.
when key is in the run or start position.
ECU and General Sensor Circuit Operation components are based on the ECU reading an out of
range voltage, or either an open or a shorted circuit. This
means that the ECU is receiving either greater than 5
Function: VDC or less than 1.0 VDC from the sensors.
Sensors provide the inputs to the ECU, which in turn When the key switch is turned to the off position the fault
provides the proper output to the injectors and ignition is stored in memory.
coils.
The ECU displays a code
to provide a visual indication of sensor/component circuit MIL Circuit Function:
integrity. These fault codes (as viewed through Service
OBD2) will aid in the diagnosis of operational problems During normal startup the MIL will illuminate until the
that may occur. engine is running. The MIL will illuminate when the input
from any one or more sensors is not operating properly.
Operating Conditions: If more than one fault exists, each fault will be displayed
using Service OBD2 in the order that they occurred.
• Key in run or start position.
• Engine running. The ECU also has many different fault codes available to
assist with diagnostics. If a malfunction is displayed, this
Theory of Operation: means that the ECU is receiving an erroneous voltage
Power is supplied to the engine electronic control unit signal, no voltage, an open or closed circuit, or a trigger
(ECU) when the key is in the run or start positions and the voltage from a sensor or component.
main engine control relay has been energized. Once a code has been read through Service OBD2, it
When the operating conditions have been met, the ECU can be matched to the fault code chart to assist in
sensors provide inputs to the ECU so that the ECU diagnosis.
will provide the ground path (low side switched) for the Limp Home Mode:
injectors at the correct time and duration.
When the ECU detects a malfunction that may cause
The ECU also has a self diagnostic mode that will display engine damage, it shuts off fuel and the ground for the
a code through Service OBD2 and illuminate the onboard rear cylinder ignition coil. This allows the engine to run,
warning light if any of the input sensors, injectors, or in a reduced capacity, to prevent engine damage and to
ignition coils are not operating properly. When the circuit allow the machine to be driven to a safe location.
is operating normally, this light will remain off.
The engine sensors are all components that change their
signal outputs to the ECU. The fault codes for these
40-45-4
Overtemp Input
If an overtemp condition exists (sensor to ground), the
coolant temperature warning indicator will flash 1 second
on, 1 second off until the condition no longer exists.
Oil Pressure Input

If a low oil pressure condition exists (<4 psi, switch to
ground), the oil pressure warning indicator will be on until
the condition no longer exists.
Coolant Temperature Gauge
Bar Graph Segment Resistance - Ohms Temperature Input Display

Segment 6 (Overtemp) — Any Temperature & Engine Segment 6 and Overtemp Light
Overtemp Input Exists Flashing
Segment 6 < 52 ±2.5 >107°C/225°F Constant
Segment 5 < 71.6 ±2.5 >97°C/207°F Constant
40-45-6
Fuel Level
Bar Graph Segment Resistance in Ohms

Segment 8 Full) <8
Segment 7 <14
Segment 6 <22
Segment 5 <31
Segment 4 <43
Segment 3 <55
Segment 2 <70
Segment 1 (Empty) <86
Open Circuit (Or Empty) Flash
Tachometer
Indicated RPM Frequency Input (Hz)

500 12.5
1000 25
1500 37.5
2000 50
2500 62.5
3000 75
40-45-7
Speedometer
Tire Size Selection Hz per 1 mph increment

14 +26.7
25 +15
26 (Default) +14.6
27 +14.4
Speed Sensor Output vs. Vehicle Speed

Frequency (Hz) kph/mph
10 1.1/0.7
210 22.7/14.1
310 33.3/20.7
410 44.1/27.4
510 54.8/34.1
610 65.6/40.8
710 76.4/47.5
Speed Sensor Frequency Amplitude

rpm Minimum Typical Maximum
50 1.1 V 1.4 V 1.7 V
400 8.2 V 9.7 V 11.2 V
3000 34 V 42 V 50 V
40-45-8
EPAM Test EPAS and EPAM are not servicable and must be replaced
This test will determine the general integrity of internal as a unit if found defective.
circuits. Measure the resistance of each pin with respect
to GND (Reference Pin). This test will only determine if
there is a possibility of internal circuitry failure.
Connector Circuit Pin Number and Polarity Resistance
4-Pin Signal Connector Speed Sensor 2 53±5% kOhm
Keyed Power 3 110±10% kOhm
LED Indicator +Ve 4 20±10% MOhm
Power Supply Connectors 12V Positive +Ve 195±15% kOhm
GND -Ve Reference Pin
Live Readings
Using Service OBD2, the live data point readings
displayed are from the engine control unit (ECU) readings
data points.
Reading Data Point Reading Units
Battery voltage volts
Coolant temperature voltage volts
Coolant temperature DegF / DegC
Cooling fan state (0=Off) (1=On)
Intake air temperature voltage volts
Intake air temperature DegF / DegC
Manifold air pressure voltage volts
Mass air flow in. of H2O
Mass air flow correction factor for altitude
Oxygen sensor voltage volts
Oxygen sensor close loop
Oxygen sensor heater (pulse width modulation) %
Engine speed rpm
Idle speed setpoint rpm
Ignition key DEG
Ignition angle ignition coil cylinder 1 DEG
Injection time (injection angle, cylinder 1) DEG
Start of injection time DEG
Stepper motor (pulse width modulation) %
Stepper motor actual position
Stepper position
Throttle position sensor DEG
Throttle position sensor voltage volts
Throttle position angle at idle DEG
40-45-10
Approved Software for Control Units
IMPORTANT: Avoid Damage! When reprogramming software. However, not all software versions
electronic control units, always comply with can be used on every machine.
the relevant instructions (e.g. installation
instructions, DTAC or PIP). NOTE: The software for reprogramming is either
Do NOT reprogram the control unit if the version
numbers of the new and current software
are identical, or if the control unit is already
programmed with a newer software version.
For the current summary of software, see PATHWAYS
NOTE: New software always includes the properties or DTAC.
40-45-11
Ground Circuit Test is between the last two test points. If a problem is
indicated, disconnect the wiring harness connector to
Reason: isolate the wire or component and check resistance
To check for opens, loose terminal wire crimps, poor again. Check connectors closely as disconnecting and
connections or corrosion in the ground circuit. The reconnecting may temporarily solve problem.
voltmeter method checks ground connections under load. Voltmeter Procedure:
NOTE: In a “switched ground” system, not all 1. Put transmission in neutral. Lock park brake.
components are grounded directly to the battery.
Some circuit grounds are activated through the 2. Raise and lock cargo box. Turn key switch to ON
electronic control module (ECM). (RUN) position.
Equipment: 3. Connect voltmeter negative (black) lead to negative (-)

terminal of battery.
• Ohmmeter or Voltmeter
4. Put meter positive (red) lead on ground terminal of
Ohmmeter Procedure: component to be tested. Be sure the component
circuit is activated (key switch ON, switches closed)
1. Turn key switch to OFF position. Engage park brake. so voltage will be present at the component. Record
voltage. Voltage must be greater than 0 but less than 1
2. Connect ohmmeter negative (black) lead to negative volt. Some components will have a very small voltage
reading on the ground side and still be operating
(—) terminal of battery. Put meter positive (red) lead correctly.
on negative terminal of battery and record reading. Specification
Reading should be within specification 1. Ground Circuit
Specification (maximum)—Voltage........................................................................1.0 V
Battery Negative Termi- Results:
nal (maximum)—Resis-
tance............................................................................................ 0.1 ohm • If resistance is above specification, check for open
wiring, loose terminal wire crimps, poor connections or
4. Put meter red lead on ground terminal of circuit or corrosion in the ground circuit.
component to be tested that is closest to the battery
negative terminal. Resistance reading must be very
• If voltage is 0, the component or wiring is open.
close to or the same as the battery negative terminal
• If voltage is greater than specification, the ground circuit
is bad. Check for open wiring, loose terminal wire
reading. Work backwards from the battery on the crimps, poor connections or corrosion in the ground
ground side of the problem circuit until the resistance circuit.
reading increases above specification. The problem
1
Some digital multimeters may not provide an accurate reading at a
very low resistance. Touch meter probe leads together, and subtract
shorted probe reading from the measured resistance reading
40-60-2
Battery Test
CAUTION: Avoid Injury! Sulfuric acid in battery

electrolyte is poisonous. It is strong enough
to burn skin, eat holes in clothing, and cause
blindness if splashed into the eyes.
Avoid the hazard by:
• Filling batteries in a well-ventilated area.
• Wearing eye protection and rubber gloves.
• Avoiding breathing fumes when
electrolyte is added.
• Avoid spilling or dripping electrolyte.
• Use proper jump-start procedure.
• If you spill acid on yourself:
• Flush your skin with water.
• Apply baking soda or lime to help
neutralize the acid.
• Flush your eyes with water for 10 - 15 minutes. Specification
Get medical attention immediately. Battery (mini-
mum)—Electrolyte Spe-
If acid is swallowed: cific Gravity...................................................................................... 1.225
• Drink large amounts of water or milk. Results:
• Then drink milk of magnesia, beaten
eggs, or vegetable oil. • If all cells are less than specification with less than 50
• Get medical attention immediately. point variation, charge battery at 10 amp rate.
• If all cells are more than specification with less than 50
Reason: point variation, load test battery. See Battery Load Test.
• If more than 50 point variation, replace battery.
To check condition of battery and determine battery
voltage. Use a voltmeter or Battery Tester to check for a minimum
battery voltage specification.
Equipment:
Specification
• Hydrometer Battery (minimum)—Volt-
• Voltmeter, Battery Test er or equivalent Procedure: age.................................................................................................12.4 V
Results:
2. Clean cable ends, battery terminals and top of battery. • If battery voltage is less than specification, charge
battery. See Charge Battery.
3. Remove battery to workbench. • If battery voltage is more than specification test
specific gravity.
4. Inspect battery terminals and case for breakage or
Install battery.
cracks.
5. Check electrolyte level in each battery cell. Add clean
distilled water as needed. If water is added, charge
battery for 20 minutes at 10 amps.
6. Remove surface charge by placing a small load on
the battery for 15 seconds.
7. Use a hydrometer to check for a minimum specific
gravity specification with less than 50 point variation
in each cell.
40-60-3
Battery Load Test

Equipment:
• Battery Tester or equivalent

Procedure:
2. Raise rear rack.
3. Clean cable ends, battery terminals and top of battery.
4. Remove battery.
5. Turn load knob (A) counterclockwise to off position.
A— Load Knob D—Amperage Reading
6. Connect tester positive (Red) cable to battery positive B—Positive (+) Terminal E—DC Volts Scale
(+) terminal (B). C—Negative (—) Terminal
7. Connect tester negative (black) cable to battery

negative (—) terminal (C).
10. Repeat Steps 7 and 8 above and read condition of
8. Turn load knob (A) of tester clockwise (in) until battery at DC Volts scale (E).
amperage reading (D) is equal to:
Results:
a. Cold cranking amperage rating of battery (use blue
scale), or: • If battery does not pass test and has not been charged,
charge battery and retest.
b. Three times ampere-hour rating (use black scale).
• If battery does not pass test and has been charged,
9. Hold for 15 seconds and turn load knob (A) of tester replace battery.
counterclockwise to off position.
Clean Battery 3. Rinse all parts with clean water. Let dry thoroughly.
NOTE: Keep cleaning solution out of battery cells. 4. Apply petroleum jelly to battery terminals to prevent
corrosion.
1. Remove battery from machine.
2. Clean battery case, battery terminals, cable ends,
bracket and/or battery box with a solution of one part
baking soda and four parts water.
40-60-5
Starter Loaded Amperage Draw Test 8. Set Digital Multimeter to DC amperage.

Reason IMPORTANT: Avoid Damage! Perform the following
To determine the amperage required to crank the engine procedure within 20 seconds to prevent
and check starting motor operation under load. damaging electrical components.
Equipment: 9. Disconnect the fuel pump connector.
• Digital Multimeter 10. Crank engine. Read and record amperage on DC amp
• Current Clamp-On Probe scale of digital multimeter.
Procedure 11. Key switch to OFF position.
1. Park machine safely. See Park Machine Safely. Results
2. Key switch OFF. • If amperage is above specification, test starter no-load

amperage and rpm to determine if starter is binding or
3. Park brake LOCKED. damaged. See Starter No-Load Amperage and RPM
Test.
4. Disconnect fuel shutoff solenoid connector.
• If starter passes no-load test but amperage draw
5. Test system ground circuit connections. See Ground remains high, check internal engine components for
Circuit Test. binding, wear or damage.
6. Load test battery. See Battery Load Test. Specification
Starting Motor @ 900
7. Connect Current Clamp-On Probe around RPM—Amperage....................................................................... 280 amp
battery positive cable.
40-60-7
Starter No-Load Amperage and RPM Test

Reason
To determine if starter is binding or has excessive
amperage draw under no-load.
Equipment:
• Digital Multimeter
• Current Clamp-On Probe
• Hand Held Digital Tachometer
• One (1) Jumper Wire
• One (1) Jumper Cable
• 12-Volt Battery
Procedure 9. Connect positive jumper cable between starter
solenoid terminal and positive battery post.
NOTE: Check that battery is fully charged and of proper
size to ensure accuracy of test. 10. Momentarily connect a jumper lead from positive
battery post to small solenoid spade terminal.
1. Park machine safely. See Park Machine Safely. Solenoid should pull in and the drive gear and shaft
should move out and spin.
2. Key switch OFF.
11. Record amperage from multimeter.
3. Park brake LOCKED.
12. Place Hand Held Digital Tachometer drive cone
4. Disconnect negative (—) battery cable clamp from against end of spinning starter drive gear and
battery. record rpm.
5. Remove and tag all wires to the starter. 13. Remove jumper from solenoid.
6. Remove starter from engine and mount to bench. Results
7. Install Current Clamp-On Probe leads as
follows:
• If amperage is above specification, check for binding
or seized bearings, sticking brushes, and dirty or worn
a. Red male plug to VOLT/OHM socket on Digital commutator. Replace starter.
Multimeter. Specification
Starting Motor
b. Black male plug to COM socket on digital multimeter.
No-Load Draw at 3000
c. Shunt black clamp to the negative (—) battery post. RPM—Amperage......................................................................... 90 amp
d. Shunt red clamp to starter case ground. • If starter passes no-load test but amperage draw
remains high when mounted on engine, check internal
8. Set digital multimeter to read 300 mV. engine components for binding, wear, or damage.
IMPORTANT: Avoid Damage! Complete the
following step in 20 seconds or less to
prevent starter damage.
40-60-8
Engine Oil Pressure Switch Test b. If there is NO continuity, replace the switch.
Reason: IMPORTANT: Avoid Damage! Do not allow
To determine if the oil pressure switch is functioning wire connector (A) to contact frame or
properly. block during test.
Equipment: 7. Start and run engine.
• Ohmmeter 8. Measure resistance between (B) and engine block.
Procedure: a. There should be NO continuity between terminal

and ground.
NOTE: Perform test with engine at room temperature.
b. If the switch DOES have continuity, check engine
1. Park machine safely. See Park Machine Safely. oil pressure. (See Oil Pressure Test in the Engine
Tests and Adjustments Section.)
2. Turn all switches to the OFF position.
c. If oil pressure is to specification, replace the oil
3. Rear rack raised. pressure switch.
4. Unplug 601 Tan wire from oil pressure switch. NOTE: BE SURE to apply Pipe Thread Sealant with
TEFLON (or equivalent) to threads of switch
5. Connect black lead of meter to engine block, red lead whenever installing switch to engine.
of meter to the oil pressure switch terminal .
6. Measure resistance between and engine block.
a. There should be continuity (<1 ohm) between
terminal and ground.
40-60-15
Fuse Test
Reason
To verify that the fuse has continuity.
Equipment:
• Ohmmeter or continuity tester
Procedure
1. Remove fuse from connector.
2. Check visually for broken filament (A).
3. Connect ohmmeter or continuity tester to ends of fuse.
4. Check for continuity. If continuity is not indicated,
replace fuse. A—Filament
Bulb Test
Reason:
To verify that the bulb has continuity.
Equipment:
• Ohmmeter or continuity tester
Procedure:
1. Park machine safely. (See the “Safety Section”.)
2. Remove bulb from socket.
3. Check visually for broken filament (A).
4. Connect ohmmeter or continuity tester to each
terminal of bulb. A—Filament
5. Check for continuity.

Results:
• If continuity is not indicated, replace bulb.
40-60-16
MXAL35282 —UN—27JUL12
Diode Test
Reason:
To verify that diode has proper continuity.
Equipment:
• Ohmmeter or Continuity Tester
A—Pin B—Pin
Procedure:
1. Park machine safely in neutral with park brake locked.
6. Reverse test leads. Check for continuity.
2. Raise hood.
Results:
3. Remove diode from connector.
Diode must have continuity in one direction only. Replace
4. Connect ohmmeter red (+) lead to pin (A) of diode.
defective diode.
5. Connect ohmmeter black (-) lead to pin (B) of diode.
Check for continuity.
Relay Test
Reason:
To check relay terminal continuity in the energized and
de-energized condition.
Procedure:
1. Park machine on level surface.
2. Engage park brake.
3. Turn key switch off.
4. Disconnect relay connector.
5. Check terminal continuity using an ohmmeter or
continuity tester.
• There should be continuity between terminals (A)
and (B), and between terminals (C) and (D).
• There should not be continuity between terminals
(E) and (B).
6. Connect a jumper wire from battery positive (+)
terminal to relay terminal (C). Connect a jumper wire
from relay terminal (D) and ground (-).
• There should be continuity between terminals (E) A—Terminal A (87a) D—Terminal D (86)
and (B). B—Terminal B (30) E—Terminal E (87)
C—Terminal C (85)
• If continuity is not correct, replace relay.
40-60-17
Speed Sensor Test

Reason:
To verify proper operation of the speed sensor.
Equipment:
• Ohmmeter
Procedure:
CAUTION: Avoid Injury! Touching hot surfaces

can burn skin. The engine, components, and
fluids will be hot if the engine has been running.
Keep hands and body away from hot surfaces
when servicing or working near the engine and A—Speed Sensor
components. Allow engine to cool.
1. Drain transaxle.
2. Remove speed sensor (A) from transmission.
Inspection:
1. Inspect speed sensor (A) for damage.
2. Test strength of internal magnet in sensor body (B)
with a ferrous metal object. Objects within 6 mm (0.25
in.) should be attracted.
A—Speed Sensor B—Sensor Body
3. Check for resistance between sensor terminals (C).

Resistance should be within specification with sensor
at room temperature.
Specification
Speed Sensor
Terminals—Resistance........................................... 3.1k Ohms DC ±10%
4. Check for continuity between each terminal and

sensor body (B). There should not be continuity.
5. With meter probes connected to each sensor terminal,
pass a ferrous metal object close to end of sensor
body. Meter should temporarily show an over limit
B—Sensor Body C—Terminals
(OL) condition as sensor impedance changes.
6. Replace sensor if any test conditions are not met.
Specification
Installation:
Speed Sensor—Torque................................................................. 11 N·m
1. Install new O-ring to speed sensor body. (97 lb.-in.)
2. Install sensor to transaxle. Tighten to specification. 3. Install wire harness connector to sensor.
4. Fill transaxle.
5. Check for leaks.
40-60-18
4WD Solenoid Test

Reason
To determine condition of the 4WD solenoid.
Equipment:
Procedure
NOTE: Access to solenoid may require removal
of front differential assembly. See Power
Train section of book.
1. Measure resistance between solenoid terminals (B) A—Solenoid Core C—Terminal

and (C). Resistance must be within specification. B—Terminal
2. Check for grounds or shorts between solenoid

terminals (B and C) and bare metal of the solenoid
Specification
core (A). There must be NO continuity between the
Solenoid Terminals (B -
core (A) and terminal (B) or (C).
C)—Resistance................................................................... 5.5 ± 2 ohms
Results • If continuity exists between terminals and core, replace
solenoid.
• If resistance between terminals is not within
specification, replace solenoid.
40-60-19
Idle Air Control Test

Reason
To test condition of the IAC (Idle Air Control) stepper coils.
Equipment:
• Ohmmeter
Procedure
1. Unplug harness from IAC device.
2. Measure resistance across terminals (A-D) and again
across terminals (B-C). Resistance values of the two
coils must be nearly equal and within specification.
Specification
IAC Terminals (A - D) and
(B - C)—Resistance............................................................40—80 ohms
3. Confirm that there is NO continuity between terminals

(A) and (B-C); repeat test with terminals (D) and (B-C).
A—Terminal D—Terminal
4. Examine plunger (E) for signs of damage or corrosion. B—Terminal E—Plunger
C—Terminal
Plunger must move in/out when moderate force is
applied.
Results • There is any continuity between the two coils.
• Plunger is damaged, corroded, or stuck.
Replace device if:
The IAC is only available as part of the throttle body
• Resistance values are not within specification. assembly.
40-60-20
Ignition Coil Test

Reason
To test condition of ignition coil windings.
Equipment:
• Ohmmeter
Procedure
1. Allow engine to cool to room temperature.
2. Unplug harness and high tension wires from coil.
3. Measure resistance across terminals (A-B).
Specification
Ignition Coil Terminals (A
- B)—Resistance..................................................................... 0.81 ohms
A—Terminal C—Terminal
4. Measure resistance from (A) to terminal (C) (inside B—Terminal
coil tower).
Specification
Ignition Coil Terminals (A • Resistance values are not within specification.
- C) Approximate—Re- • Coil is damaged.
sistance................................................................................. 10.6K ohms
Should tests be inconclusive, exchange ignition coil with
5. Examine outside of coil for cracks or burns. that of adjacent cylinder and observe any change in
operation.
Results
Replace coil if:
Fuel Injector Test

Reason
To test condition of fuel injector coil.
NOTE: This test only checks the fuel injector coil.
Equipment:
• Ohmmeter
Procedure
2. Unplug harness from fuel injector.
3. Measure resistance across terminals (A - B).
Specification
Fuel Injector Terminals
(A - B) @ 20° C (68°
F)—Resistance......................................................................12—16 ohm
A—Terminal B—Terminal
Results
Replace fuel injector if coil resistance is not within
specifications, or if the injector continues to have fuel
delivery problems after being cleaned.
40-60-21
Knock Sensor Test

Reason
To test operation of knock sensor.
Equipment:
Procedure
2. Unplug harness from knock sensor.
3. Measure resistance across terminals (A-B).
Resistance must be greater than specification.
Specification
Knock Sensor
Terminals (A - B) A—Terminal B—Terminal
Minimum—Resistance..................................................... 1M (106) ohms
4. Set multimeter to low-range AC volts. Tap the area

around the knock sensor with a small hammer and • Resistance measures less than specification.
check for an AC signal from terminals (A-B). • No output voltage is observed.
Specification
Results Knock Sensor—Torque.................................................................20 N·m
(177 lb.-in.)
Replace knock sensor if:
Fuel Pump Relay Command Test

NOTE: Allow sufficient time between repeated tests
Using Service OBD2, this test will activate fuel pump as the fuel pump may overheat with repeated
relay with the key switch on, engine not running. Test will cycling without allowing time to cool.
continue for 30 seconds. If engine is running, RPM will
increase. Component Command Command
Fuel Pump Relay
Cooling Fan Relay High Command Test NOTE: This test will not activate the cooling fan relay itself.
Using Service OBD2, this test will activate the coolant Component Command Command
overtemp warning light on the display panel. Cooling Fan Relay and Overheat
Lamp
Cooling Fan Relay Low Command Test Component Command Command

Cooling Fan Relay
Using Service OBD2, this test will activate the coolant fan
relay and turn the cooling fan on.
40-60-22
Component Command Command

Main Relay Command Test
Main Relay
Using Service OBD2, this command will cause the
main relay to turn on and energize all circuits that are
active and rely on the relay to function.
Component Command Command

Cylinder Shut-off Command Test
Cylinder
Using Service OBD2, this test will shut off the selected Reading Data Point Reading
cylinder’s operation. Engine Speed (rpm)
Ignition Coil 1 Command Test Component Command Command

Ignition Coil 1
Using Service OBD2, this test will fire ignition coil 1
repeatedly.

Ignition Coil 2
Using Service OBD2, this test will fire ignition coil 2
repeatedly.

Ignition Coil 3
Using service OBD2, this test will fire ignition coil 3
repeatedly.
40-60-23
Specifications
Transmission Case Bolts Torque 28 N·m

(21 lb.-ft.)
Gearbox Case 37 N·m
(26 lb.-ft.)
Pinion Gear—Flat Face of Gear Distance 33.6 ± 0.05 mm
to Top of Housing (1.323 ± 0.002 in.)
Output Shaft Backlash 0.2—0.3 mm
(0.008—0.012 in.)
Bevel Gearbox to Transmission Torque 37 N•m
Case Bolts (26 lb.-ft.)
Ball Joint Nuts Torque 73 N·m
(54 lb.-ft.)
Front Differential
Differential to Frame Bolts Torque 81 N·m
(60 lb.-ft.)
Front Differential Case Bolt Torque 23 N·m
(204 lb.-in.)
Gear Backlash 0.10—0.25 mm
(0.004—0.010 in.)
Gear Case Drain Plug Torque 12 N·m
(110 lb.-in.)
Gear Case Fill Plug Torque 12 N·m
(110 lb.-in.)
Axle Castle Nut Torque 170 +119/-23 N·m
(125 +88/-17 lb.-ft.)
Suspension Arm to Bearing Torque 116 N·m
Carrier Nut (86 lb.-ft.)
Suspension Arm to Frame Torque 116 N·m
(86 lb.-ft.)
Brake Caliper Sliding Pin Torque 46 N·m
(34 lb.-ft.)
Rear Wheel Lug Bolts
Wheel Lug Bolt (Alloy Wheel) Torque 142 N·m
(105 lb.-ft.)
Ball Joint to A-Arm Locknut Torque 54 N·m
(40 lb.-ft.)
50-05-3
Diagnostics
Test Conditions:
Diagnose Drive Train
• Engine OFF.
Diagnose Drive Train • Rear wheels supported off floor.
• Air pressure equal in driving tires. Driving tires close to same radius.
Drive Train Checks
• Drive Belt Is the drive belt in good condition? YES: Go to next step.
NO: Replace drive belt.
• Shift Linkage Shift linkage shifts to forward high and low, neutral, and reverse and stays in gear
during operation?
NO: Adjust shift linkage.

(See Transmission Shift
Adjustment.)
• Axles Axles rotate smoothly and quietly; no free play in axles, bearings or housings? YES: Go to next step.
NO: Check axles and

housings.
• Brakes Are the brakes dragging? YES: Adjust or repair

brakes. Refer to Brakes
section.
• Differential Lock Differential lock engages and disengages? YES: Go to next step.
NO: Adjust differential

lock. (See Differential Lock
Adjustment.)
•
6 (continued) Differential lock produces ratcheting sound in transaxle? YES: Check internal
components.
50-20-1
Steering
Contents
Page
Page
Steering Components.................................... 60-10-1 Ball Joint Removal and
Steering Components With EPAS.................. 60-10-2 Installation ................................................. 60-30-4
Front Suspension .......................................... 60-10-3 Steering Wheel Removal and
Front Suspension .......................................... 60-10-4 Installation ................................................. 60-30-5
Rear Suspension ........................................... 60-10-6
Rear Suspension ........................................... 60-10-7
Group 15—Theory of Operation Steering Shaft Removal and

Steering ......................................................... 60-15-1 Installation ................................................. 60-30-8
Steering Shaft Removal and
Installation (EPAS)................................... 60-30-11
Steering Shaft Bearing
Group 20—Diagnosis Replacement ........................................... 60-30-14
Steering Pulls In One Direction .....................60-20-1 Steering Gearbox ........................................ 60-30-15
Steering Pulls In One Direction .....................60-20-1 Front Coilover Shock Absorber
Steering Wanders or Vibrates........................60-20-2 Removal and Installation ......................... 60-30-19
Steering Wanders or Vibrates........................60-20-2 Rear Coilover Shock Absorber
Wheel Bearing Noise.....................................60-20-4 Removal and Installation ......................... 60-30-20
Wheel Bearing Noise.....................................60-20-4 Tie Rod End Removal and
Steering Hard in Left, Right, or Both Replacement ........................................... 60-30-21
Directions ..................................................60-20-4 Front Suspension Arm Removal
Steering Hard in Left, Right, or Both and Installation ........................................ 60-30-22
Directions ..................................................60-20-5 Rear Axle Bearing Carrier ........................... 60-30-24
Steering Locks In Hard Left or Right Rear Suspension Arm Removal
Turn ...........................................................60-20-6 and Installation ........................................ 60-30-29
Steering Locks In Hard Left or Right Front Suspension Arm Bushing
Turn ...........................................................60-20-6 Removal and Installation ......................... 60-30-31
Steering Wheel Pulls Upward........................60-20-7 Rear Suspension Arm Bushing
Steering Wheel Pulls Upward........................60-20-7
Steering Wheel Spins Freely .........................60-20-8
Steering Wheel Spins Freely .........................60-20-8
Noise During Turns Over Rough
Terrain .......................................................60-20-9
Noise During Turns Over Rough
Terrain .......................................................60-20-9

Specifications ................................................ 60-25-1
Service Equipment and Tools ........................ 60-25-1
Centering Steering Rack ............................... 60-25-2
Centering Steering Wheel ............................. 60-25-3
Suspension Adjustment................................. 60-25-4
Toe-In Adjustment.......................................... 60-25-6
Rear Wheel Camber Adjustment................... 60-25-7
Group 30—Repair
Specifications ................................................ 60-30-1
Other Material................................................ 60-30-2
Steering Knuckle Removal and
Installation ................................................. 60-30-2
Front Wheel Bearing Removal and
Replacement ............................................. 60-30-4
60-1
Theory of Operation
Steering A steering wheel is connected via shafts and U-joints to the
Function: gearbox pinion. Rotation of the pinion moves the enclosed
rack laterally to the left or right. Tie rods at each end of the
The steering system provides a means of turning the rack are connected to corresponding front wheel spindle
machine when in motion. assemblies. The tie rods are adjustable in length for proper
front wheel alignment. The tie rod ends are sealed ball
Theory of Operation: and socket units which provide consistent steering control
The steering system uses a rack and pinion type gearbox. through the range of front wheel suspension movement.
The steering gearbox is a sealed unit with no serviceable
parts.
60-15-1
Diagnosis
Steering Pulls In One Direction
Steering Pulls In One Direction
• Steering Pulls In One Direction
• Test Procedure Is the load being carried centered in the cargo box? NO: Position load
for equalized weight
distribution.
• (Continued) Are tires out of round or unequally inflated? YES: Inflate to proper air
pressure. Replace tire(s) as
needed.
• (Continued) Are tires of equal size? NO: Replace tire(s) so that

axle pair tires are of equal
size.
•
1D (Continued) Have wrong size tire(s) been installed? YES: Replace with correct
size tires.
•
1E (Continued) Are left and right spring compression adjusters set to same position on front or rear axle? NO: Set left and right
spring adjusters to same
position.
•
1F (Continued) Is toe-in out of specification? YES: Adjust toe-in as
needed. See Toe-In
Adjustment.
•
1G (Continued) Are tie rods bent or loose? YES: Repair or replace as
needed. See Tie Rod End
Removal and Replacement.
60-20-1
Diagnosis
• (Continued) Are wheel bearings worn or lacking lubrication? YES: Replace as needed.
See Front Wheel Bearing
• (Continued) Do spindles, ball joints, or suspension arm bearings require lubrication? YES: Lubricate as needed.
• (Continued) Is the rack and pinion assembly worn or broken? YES: Repair or replace
as needed. See Steering
Gearbox.
• (Continued) Are the suspension arm bushings worn, or is suspension arm bent? YES: Repair or replace as
needed.
• (Continued) Are shock absorber mounts bent, or have worn, loose, broken, or missing hardware? YES: Repair or replace as
needed. See Front Coilover
Shock Absorber Removal
and Installation.
• (Continued) Are A-frame bushings worn? YES: Repair or replace

as needed. See Front
Suspension Arm Bushing
Steering Wanders or Vibrates

Steering Wanders or Vibrates
• Steering Wanders or Vibrates
• Test Procedure Does the load being carried exceed the machine’s rated capacity? YES: Reduce load weight.
60-20-2
Diagnosis
• (Continued) Are tires out of round or improperly inflated? YES: Inflate to proper air
pressure. Replace tire(s) as
needed.
• (Continued) Are tires of equal size? NO: Replace tire(s) so that

axle pair tires are of equal
size.
• (Continued) Have the wrong size tire(s) been installed? YES: Replace with correct
size tires.
• (Continued) Are left and right spring compression adjusters set to same position on front or rear axle? NO: Set left and right
spring adjusters to same
position.
• (Continued) Are front or rear spring compression adjusters properly set for the load being carried? NO: Set spring adjusters to
correct chassis ride height
for load being carried.
• (Continued) Are the tie rods bent or loose? YES: Repair or replace as
• (Continued) Are wheel bearings worn or lost lubrication? YES: Replace as needed.
• (Continued) Is toe-in out of specification? YES: Adjust toe-in as

needed. See Toe-In
Adjustment.
• (Continued) Do spindles, king pins, or king pin A-frame bearings require lubrication? YES: Lubricate as needed.
60-20-3
Diagnosis
Gearbox.
• (Continued) Are suspension arm bushings worn, or suspension arms bent? YES: Repair or replace as
needed.
• (Continued) Are shock absorber mounts bent, or is hardware worn, loose, broken, or missing? YES: Repair or replace as
and Installation.
• (Continued) Are suspension arm bushings worn? YES: Repair or replace

Wheel Bearing Noise

Wheel Bearing Noise
• Wheel Bearing Noise
• Test Procedure Are wheel bearings worn or lost lubrication? YES: Replace as needed.
• (Continued) Is the axle nut loose? YES: Remove cotter pin,

tighten nut to specified
torque, and install new
cotter pin.
Steering Hard in Left, Right, or Both

Directions Steering Hard in Left, Right, or Both Directions
60-20-4
Diagnosis
• Steering Hard in Left, Right, or Both Directions
• Test Procedure Are optional accessories (cab, blade, etc.) installed? YES: Install heavy duty
shock absorber kit.
• (Continued)
• (Continued) Are tie rods bent or loose? YES: Repair or replace as

• (Continued) Are wheel bearings worn or lacking lubrication? YES: Repair or replace as
needed. See Front Wheel
Bearing Removal and
Replacement.
• (Continued) Have wrong size tire(s) been installed? YES: Replace with correct
size tires.
• (Continued) Is front wheel toe-in out of specification? YES: Adjust toe-in as

needed. See Toe-In
Adjustment.
60-20-5
Diagnosis
Gearbox.
• (Continued) Are suspension arm bushings worn, or suspension arms bent? YES: Repair or replace as
needed.
and Installation.
• (Continued) Are suspension arm bushings worn? YES: Repair or replace

• (Continued) Are steering wheel or shaft splines worn or stripped? YES: Repair or replace
Gearbox.
• (Continued) Is steering rack rubber boot cracked or torn? YES: Replace as needed.
See Steering Gearbox.
60-20-6
Diagnosis
Gearbox.
• (Continued) Are suspension arm bushings worn, or is suspension arm bent? YES: Repair or replace as
needed.
and Installation.

Gearbox.
• (Continued) Is the steering rack rubber boot cracked or torn? YES: Replace as needed.
Steering Wheel Pulls Upward

Steering Wheel Pulls Upward
• Steering Wheel Pulls Upward
60-20-7
Diagnosis
• Test Procedure Is the steering wheel nut loose, stripped, or missing? YES: Tighten or replace as
needed.
• (Continued) Is the snap ring at the bottom of the steering shaft support displaced from the steering
shaft groove?
YES: Seat snap ring to
steering shaft groove.
• (Continued) Is the bolt securing steering shaft to rack and pinion assembly loose or missing? YES: Install and secure
bolt to specified torque. See
Steering Gearbox.
Steering Wheel Spins Freely

Steering Wheel Spins Freely
• Steering Wheel Spins Freely
• Test Procedure Is the steering wheel nut loose, stripped, or missing? YES: Tighten or replace as
needed.
• (Continued) Are steering wheel or shaft splines worn or stripped? YES: Replace as needed.
• (Continued) Is the bolt securing steering shaft to rack and pinion or power assist assembly loose or
missing?
YES: Install and secure
bolt to specified torque. See
Steering Gearbox or (SEE
Electric Power Assisted
Steering (EPAS) Module
Removal and Installation.).
60-20-8
Diagnosis
Noise During Turns Over Rough Terrain

Noise During Turns Over Rough Terrain
• Noise During Turns Over Rough Terrain
• (Continued) Are tie rods bent or loose? YES: Repair or replace as

• (Continued) Are wheel bearings worn or lacking lubrication? YES: Replace as needed.
• (Continued) Is toe-in out of specification? YES: Adjust toe-in as

needed. See Toe-In
Adjustment.
Gearbox.
60-20-9
Diagnosis
• (Continued) Are suspension arm bushings worn, or is suspension arm bent? YES: Repair or replace as
needed.
• (Continued) Are stabilizer bar bushings loose or missing? YES: Tighten bushing
mount hardware.
YES: Replace bushings.

• (Continued) Are stabilizer bar end links loose? YES: Tighten hardware
securing links.
YES: Replace links.

and Installation.

Gearbox.
• (Continued) Is the steering rack rubber boot cracked or torn? YES: Replace as needed.
60-20-10
Specifications
Tie Rod Jam Nut Torque 95 N·m

(70 lb.-ft.)
Steering Wheel Nut Torque 38 N·m
(28 lb.-ft.)
Tire Inflation Pressure
Front Tires—All Brands Pressure 48 kPa
(7 psi)
Rear Tires—All Brands Pressure 48 kPa
(7 psi)
Axle Bearing Carrier to Suspension Torque 116 N·m

Arm Bolt (86 lb.-ft.)
Shock Absorber to Suspension Torque 116 N·m
Arm Bolt (86 lb.-ft.)
Wheel Lug Bolts

Alloy Wheel Torque 142 N·m
(105 lb.-ft.)
Service Equipment and Tools

Digital Level ................................................. not applicable Used to check rear wheel camber.
60-25-1
5. If tire contacts suspension arm in either direction,

adjust tie rods to center steering.
NOTE: The steering rack rubber boot may turn with the tie
rod if the boot clamp is too tight. Loosen the clamp
enough to allow the rubber boot to remain stationary.
a. Loosen tie rod jam nuts (B).

b. Rotate tie rod by placing wrench on hex (C).
c. Loosen boot clamps (D) if necessary to prevent
boot rotation with tie rod adjustment.
d. Lengthen tie rod to reduce clearance between tire
and suspension arm on the adjusted side.
e. Shorten tie rod to increase clearance between tire B—Jam Nut D—Boot Clamp
C—Hex on Tie Rod
and suspension arm on the adjusted side.
f. Tighten tie rod jam nuts to specification.
Specification
Tie Rod Jam
Nut—Torque..................................................................................95 N·m
(70 lb.-ft.)
60-25-2
Suspension Adjustment
Suspension adjustments can be made to accommodate
load changes on the machine. Spring compression
adjusters are installed on the coil springs on each shock
absorber.
Base Suspension Adjustment
Adjustment of the base suspension is limited to static
spring compression adjustment. The higher settings
(greater spring compression) provide for increased ride
height or resistance to chassis squat with heavier loads.
1. Park machine safely. (See Park Machine Safely.)
2. Raise and safely support machine, removing load A—Spring Compression C—Stop
from suspension. Adjuster
B—Notch
NOTE: Spring compression must be adjusted to the same
setting at each side of the front or rear axle.
3. Rotate spring compression adjuster (A) with provided b. Rotate adjuster until adjustment notch is seated
adjustment tool to increase or decrease spring over stop (C) on shock absorber body for desired
compression as needed. spring compression.
a. Fit adjustment tool to notch (B) in adjuster. 4. Remove supports and lower machine.
60-25-4
Performance Suspension Adjustment

Available performance shock absorbers can be adjusted
for static spring compression and compression damping
stiffness.
Increased static spring compression provides for
increased ride height or resistance to squat with heavier
loads. Reduced compression provides greater ride
comfort when a lighter or no cargo load is carried.
Adjustment of damping stiffness provides a means of
controlling suspension reaction to surface or terrain
irregularities for increased ride comfort or chassis stability.
1. Park machine safely on a flat, level surface. (See Park
Machine Safely.) Rear shock absorber shown, front adjustment is similar.
2. Check tire pressure. Adjust to specification.
A—Jam Nut C—Control Knob
Tire Inflation Pressure—Specification Front
B—Notch
Tires—All
Brands—Pressure......................................................................... 48 kPa
(7 psi)
Rear Tires—All Brands d. Tighten jam nut.
5. Remove supports and lower machine.
Pressure................................................................ 48 kPa
(7 psi) 6. Measure chassis height from the surface to a common
reference point (such as the bottom of the fender) on
both sides of the machine at the axles. The measured
distances must be nearly equal at the front or rear.
IMPORTANT: Avoid Damage! Shock absorber
compression damping adjusters have a limited
range of adjustment. Do not attempt to adjust
damping beyond the internal stop in either
direction. Forcing the damping adjuster beyond
the stops can damage the internal valving.
3. Raise and safely support machine, removing load NOTE: Shock absorber damping must be adjusted
from suspension. equally at each side of the front or rear axle.
NOTE: Spring compression must be adjusted equally
7. Rotate control knob (C) at shock absorber reservoir to
at each side of the front or rear axle.
adjust damping stiffness. Shock absorber damping
must be adjusted equally at each side of the front or
4. Increase or decrease spring compression as required
rear axle.
for cargo load or ride comfort.
a. Loosen jam nut (A). • Rotate knob clockwise to increase compression
damping stiffness.
b. Fit adjustment tool to notch (B) in adjusting ring. • Rotate knob counterclockwise to decrease
compression damping stiffness.
c. Rotate threaded adjuster to increase or decrease
static spring compression as needed. Adjust spring
compression equally at each side of the front or
rear axle.
60-25-5
Toe-In Adjustment
In order to set front wheel toe-in accurately, suspension,
and steering components must be in good condition. All
fasteners must be tightened to specification.
NOTE: Toe-in cannot be correctly adjusted with the front
wheels off the surface, on an uneven surface, or
with any weight or load on the machine.
1. Park machine safely on a hard level surface. (See

Park Machine Safely.)
2. Turn steering wheel so that front tires are in
straight-ahead position.
3. Check tire pressure. Adjust to specification if needed.
Specification
Front Tires—All
Brands—Pressure......................................................................... 48 kPa
(7 psi)
4. Measure front wheel hub center height (A) from

surface.
5. Mark tread centerline (B) and hub center height at
front and back of both front tires.
6. Measure distance (C) between tread center lines at

rear of tires at hub height.
7. Measure distance (D) between tread center lines at
front of tires at hub height.
8. Subtract front measurement from rear measurement
to determine toe-in.
C—Tread Centerline―Rear of D—Tread Centerline―Front of

Tires Tires
60-25-6
NOTE: If the tie rod boot clamp is too tight, the steering
rack rubber boot can turn with the tie rod. Loosen
the boot clamp enough to allow the rubber boot to
remain stationary when the tie rod is turned.
9. Adjust toe-in if not within specification.

Specification
Toe-In (Front
Wheel)—Distance..................................................................... 4 ± 3 mm
(0.16 ± 0.12 in.)
a. Loosen jam nuts (E) on left and right tie rod.

b. Rotate tie rod by placing wrench on hex (F).
c. Loosen boot clamps (G) if necessary to prevent Left side shown.
boot rotation with tie rod adjustment.
E—Jam Nut G—Boot Clamp
d. Adjust left and right tie rods equally until toe-in is F— Hex on Tie Rod
within specification.
e. Tighten jam nuts to specification.
Specification
f. Check that front tires do not contact suspension
Tie Rod Jam
when turned fully left or right.
Nut—Torque..................................................................................95 N·m
(70 lb.-ft.)
60-25-7
Repair
Specifications
Wheel Lugs
(105 lb.-ft.)
Axle Castle Nut Torque 170 +119/-23 N·m

(125 +88/-17 lb.-ft.)
Ball Joint to Suspension Arm Torque 54 N·m
Lock Nut (40 lb.-ft.)
Caliper Sliding Pins to Steering Torque 46 N·m
Knuckle (34 lb.-ft.)
Camber (Rear Wheel) Angle 0°
Tie Rod End to Steering Arm Nut Torque 54 N·m
(40 lb.-ft.)
Steering Wheel Nut Torque 38 N·m
(28 lb.-ft.)
Shock Absorber Mounting Bolt Torque 126 N·m
(93 lb.-ft.)
Steering Shaft to Pinion Input Torque 50 N·m

Pinch Bolt (37 lb.-ft.)
Lower Steering Shaft to Steering Torque 50 N·m
Gear Pinion Shaft Pinch Bolt (37 lb.-ft.)
Steering Rack to Frame Nuts Torque 28.5 N·m
(21 lb.-ft.)
Tie Rod End to Steering Arm Torque 54 N·m
Lock Nut (40 lb.-ft.)
Tie Rod End to Steering Knuckle Nut Torque 54 N·m
(40 lb.-ft.)
Tie Rod End to Tie Rod Jam Nut Torque 95 N·m
(70 lb.-ft.)
Suspension Arm to Frame Nut Torque 116 N·m
(86 lb.-ft.)
Suspension Arm to Bearing Torque 116 N·m
Carrier Nut (86 lb.-ft.)
60-30-1
Repair
Ball Joint to Suspension Arm Nut Torque 54 N·m

(40 lb.-ft.)
Brakes
Brake Hose Retainer Bolt Torque 17 N·m
(150 lb.-in.)
Brake Caliper Sliding Pin Torque 46 N·m
(34 lb.-ft.)
60-30-2
Repair
Tie Rod Boot Replacement:

Tie rod boot replacement can be carried out with the
gearbox installed.
1. Remove tie rod end from steering knuckle. See Tie
Rod End Removal and Replacement.
2. Note number of exposed threads (A) on tie rod end.
3. Loosen tie rod jam nut (B), and remove tie rod end.
4. Remove wire tie (C) securing boot to steering rack Steering gearbox shown removed for clarity.
body.
A—Tie Rod―Exposed Threads C—Wire Tie
5. Remove clamp (D) securing boot to tie rod. B—M12 Jam Nut D—Clamp
6. Remove boot from rack body and tie rod.
7. Install new boot. Ensure that boot ends are installed 10. Check front wheel toe-in. See Toe-In Adjustment.
to recesses in rack body and tie rod.
11. Tighten tie rod jam nut.
8. Secure boot to rack body with wire tie. Secure boot
to tie rod with clamp.
9. Reinstall tie rod end with jam nut to tie rod, ensuring
that original number of threads are exposed.
60-30-16
Brakes
Contents
Page
Page
Specifications ................................................ 70-05-1 Bleeding Master Cylinder .............................. 70-25-5
Essential or Recommended Tools.................. 70-05-2 Burnish Brakes .............................................. 70-25-6
Other Material................................................ 70-05-3
Group 30—Repair
Group 10—Component Location Summary of References................................ 70-30-1
Brake System ................................................ 70-10-1 Brake Pad Replacement................................ 70-30-1
Brake System Components - Master Cylinder Removal and
Front .......................................................... 70-10-2 Installation ................................................. 70-30-4
Brake System Components - Brake Line Removal and
Rear........................................................... 70-10-3 Replacement ............................................. 70-30-7
Park Brake Components ............................... 70-10-4 Brake Caliper Removal and
Park Brake Housing Components.................. 70-10-5 Installation ............................................... 70-30-17
Brake Rotor Removal and
Group 15—Theory of Operation Inspection ................................................ 70-30-19
Brake System ................................................ 70-15-1 Brake Pedal Removal and
Installation ............................................... 70-30-21
Group 20—Diagnosis
Brake System Diagnosis Checks .................. 70-20-1
Hydraulic Brakes ...........................................70-20-1
Brakes Will Not Engage or Show Poor Installation ............................................... 70-30-24
Response ..................................................70-20-1 Park Brake Removal, Service, and
Brakes Will Not Engage or Show Poor Replacement ........................................... 70-30-26
Response ..................................................70-20-1
Brake Effort Excessive ..................................70-20-2
Brake Effort Excessive ..................................70-20-2
Wheel Brakes Will Not Release.....................70-20-2
Wheel Brakes Will Not Release.....................70-20-2
Brake Noisy or Chattering .............................70-20-3
Brake Noisy or Chattering .............................70-20-3
Excessive Brake Pad Wear ...........................70-20-3
Excessive Brake Pad Wear ...........................70-20-3
Brake Pedal Travel Excessive.......................70-20-3
Brake Pedal Travel Excessive.......................70-20-4
Brakes Pull Left or Right................................70-20-4
Brakes Pull Left or Right................................70-20-4
Brake Pedal Is Hard With Little
Movement .................................................70-20-4
Pedal Feels Hard With Little
Travel ........................................................70-20-4
Park Brake Will Not Engage or
Hold...........................................................70-20-5
Park Brake Will Not Engage or
Hold...........................................................70-20-5
Park Brake Will Not Release .........................70-20-5
Park Brake Will Not Release .........................70-20-5

Summary of References................................ 70-25-1
Check Brake Fluid Level................................ 70-25-1
Check Park Brake Lubricating Oil
Level .......................................................... 70-25-2
Master Cylinder Rod Adjustment................... 70-25-2
Bleeding Brakes ............................................ 70-25-4
70-1
Specifications
Specifications
Brake Specifications:
Brake Type Four Wheel Hydraulic Disk
Park Brake Type Mechanical Wet Disk
Hydraulic Brakes:
Brake Line 3-Way Block Bolt 10.4 N·m
(92 lb.-in.)
Park Brake Housing
Park Brake Lubricant (approx.) Volume 50 mL (1.7 oz)
Park Brake Housing Fill Plug Torque 4 N·m
(35 lb.-in.)
Park Brake Housing Level Plug Torque 4 N·m
(35 lb.-in.)
Housing Plug - Brake Hold Tool Torque 15 N·m
(132 lb.-in.)
Housing Level Plug Torque 15 N·m
(132 lb.-in.)
Wheel Lugs
(105 lb.-ft.)
Brake Arm to Bracket Distance 1—2 mm

(0.039—0.079 in.)
Brake Push Rod Jam Nut Torque 20 N·m
(177 lb.-in.)
Master Cylinder Banjo Fitting Bolt Torque 27 N·m
(20 lb.-ft.)
Master Cylinder to Mount Nut Torque 40 N·m
(30 lb.-ft.)
Brake Friction Material (Minimum) Thickness 1 mm
(0.04 in.)
Rotor (Minimum) Thickness 4.76 mm
(0.19 in.)
Front Caliper Sliding Pins Torque 46 N·m
(34 lb.-ft.)
Caliper Banjo Fitting Bolt Torque 27 N·m
(20 lb.-ft.)
Rear Caliper Sliding Pins Torque 46 N·m
(34 lb.-ft.)
Brake Rod Jam Nut Torque 20 N·m
(15 lb.-ft.)
Brake Line Retainer to Chassis Torque 10.4 N·m
(92 lb.-in.)
70-05-1
Specifications
Brake Line Flare Nut to Fitting Torque 15 N·m

(133 lb.-in.)
Axle Castle Nuts (Minimum) Torque 102 N·m
(78 lb.-ft.)
Axle Castle Nuts (Maximum) Torque 244 N·m
(180 lb.-ft.)
Cable End to Actuator Shoulder Bolt Torque 9 N·m
(80 lb.-in.)
Park Brake Control to Mounting Torque 28 N·m
Bracket Nut (20 lb.-ft.)
Mounting Bracket to Frame Bolt Torque 28 N·m
(20 lb.-ft.)
Friction Disk Holding Screw Torque 8 N·m
(Maximum) (60 lb.-in.)
Friction Disk (Minimum) Thickness 2 mm
(o.080 in.)
End Plate to Housing Bolt Torque 19 N·m
(168 lb.-in.)
Park Brake to Gearbox Bolt Torque 102 N·m
(75 lb.-ft.)
Cable to Actuator Shoulder Bolt Torque 9 N·m
(80 lb.-in.)
70-05-2
Specifications
Other Material
Number Name Use
NA (U.S.) DOT 4 Brake Fluid Use to fill brake reservoir.
20C (U.S.) Park Brake Housing Lubricant Used to fill park brake system.
NA (U.S.) ANTI-SEIZE Compound Apply to brake caliper sliding pins.
25C (U.S.) Grease Apply to brake rotor hub bearing

surface and to drive splines.
70-05-3
Diagnosis
Brake System Diagnosis Checks
System Checks:
Hydraulic Brakes
Step 1 Is the brake fluid level correct? YES: Go to next step.

NO: Add brake fluid.
Check system for leaks.
Step 2 Do brake system components leak? YES: Tighten, repair, or

replace components as
necessary. Bleed brake
system. See Bleeding
Brakes.
Step 3 Is there air in the brake system? YES: Bleed the brake
system. See Bleeding
Brakes.
Brakes Will Not Engage or Show Poor

Response Brakes Will Not Engage or Show Poor Response
Brakes Will Not Engage or Show Poor Response
Step 1 Is the brake fluid level low? YES: Add brake fluid. See
Check Brake Fluid Level.
Step 2 Do the master cylinder seal, brake lines or brake caliper seals leak? YES: Repair or replace
components
Step 3 Is there air in the brake system? YES: Bleed brake lines.
See Bleeding Brakes.
Step 4 Is the master cylinder push rod adjusted correctly? YES: Adjust push rod
length. See Master Cylinder
Rod Adjustment.
Continued on next page OUMX258,0000616 -19-18OCT12-6/7
70-20-1
Diagnosis
Step 5 Is the brake pedal or pivot bent, broken or worn? YES: Repair or replace
components as needed.
Brake Effort Excessive

Step 2 Does the master cylinder leak? YES: Repair or replace

components.
Step 3 Is the master cylinder push rod adjusted correctly? NO: Adjust push rod
Rod Adjustment.
Step 5 Are brake pads excessively worn? YES: Replace brake

pads. See Brake Pad
Replacement.
Wheel Brakes Will Not Release

Rod Adjustment.
70-20-2
Diagnosis
Brake Noisy or Chattering

Step 1 Do the brake calipers leak? YES: Repair or replace

components.
Step 2 Do the brake calipers have loose or missing hardware? YES: Repair or replace
hardware.
Step 3 Are brake pads excessively worn? YES: Replace brake

pads. See Brake Pad
Replacement.
Excessive Brake Pad Wear

Step 1 Is the brake pedal return spring stretched, broken or missing? YES: Replace spring.
Step 2 Is the master cylinder push rod adjusted correctly? NO: Adjust push rod
Rod Adjustment.
Brake Pedal Travel Excessive

70-20-3
Diagnosis
Step 2 Do the master cylinder seal, brake lines or brake caliper seals leak? YES: Repair or replace
components.
Brakes Pull Left or Right

Step 2 Do the brake lines or brake calipers leak? YES: Repair or replace
components.
Brake Pedal Is Hard With Little Movement

Brake Pedal Is Hard With Little Movement
Pedal Feels Hard With Little Travel
Rod Adjustment.
70-20-4
Diagnosis
Park Brake Will Not Engage or Hold

Step 1 Is the park brake cable broken? YES: Replace cable.

NO: Go on to next step.
Step 2 Does differential lock engage when park brake is applied? NO: Adjust, repair, or
replace components as
needed.
YES: Go on to next step.
Step 3 Is the park brake lever or locking pawl bent, broken, binding or worn? YES: Repair or replace
Step 4 Is the park brake cable stretched or binding? YES: Replace brake cable.
See Park Brake Control
Cable Replacement.
Step 5 Does the park brake mechanism have missing or worn components? YES: Replace
components.
Step 6 Are park brake friction disks worn below minimum thickness? YES: Replace friction
disks.
Park Brake Will Not Release

Step 1 Is the park brake cable bent or frayed? YES: Replace cable.
70-20-5
Diagnosis
Step 2 Is the park brake cable binding? YES: Repair or replace

brake cable. See Park
Brake Control Cable
Replacement.
Step 3 Is the park brake lever or locking pawl bent, broken, binding, or worn? YES: Repair or replace
70-20-6
Summary of References • Bleeding Brakes
• Check Brake Fluid Level • Bleeding Master Cylinder
• Check Park Brake Lubricating Oil Level • Burnish Brakes
• Master Cylinder Rod Adjustment
Check Brake Fluid Level

IMPORTANT: Avoid Damage! Avoid contamination
of the brake fluid. Thoroughly clean area
around the filler cap before removing. Do
not open the brake fluid reservoir cap
unless absolutely necessary.
Use extreme care when filling the reservoir. Fluid
spilled on painted surfaces can cause damage.
Use only DOT 4 brake fluid from a
sealed container.
1. Park machine safely on a level surface. See Park

Machine Safely.
A—Low Level Line B—High Level Line
CAUTION: Avoid Injury! Allow the radiator to cool.

Serious burns can result from contact with a hot
radiator. Wear protective gloves when working 4. If fluid is low, carefully clean area around reservoir cap
around the radiator or center console. Injury and remove cap.
can result from contact with sharp edges.
• Add fluid as required to maintain within specified
levels.
2. Open hood.
5. Install reservoir cap.
3. Visually check brake fluid level.
6. Close hood.
• Fluid level must be maintained between low (A) and
high (B) level marks.
70-25-1
Specifications
Seat Bracket Nuts Torque 10 N·m (88 lb-in.)

Adjuster Rail to Seat Base Bolt Torque 28 N·m (20 lb-ft)
Seat Frame Bolt Torque 28 N·m (20 lb-ft)
Seat Adjuster Rail to Seat Base Torque 28 N·m (20 lb-ft)
Storage Box to Seat Base Bolt Torque 28 N·m (20 lb-ft)
Prop Rod Push-On Nut Depth 20 mm (0.8 in.)
Seat Bracket Nuts Torque 10 N·m (88 lb-in.)
(88 lb.-in.)
Other Material
Number Name Use
NA (U.S.) Cooling System Cleaner Used to flush cooling
system.
NA (U.S.) Oreion Motors Cooling Used to flush cooling system.
System Quick Flush
80-05-2
Service Tools and Kits
...................... Park Brake Pack Holding Tool Tool presses brake plates together to maintain alignment
during park brake installation.
Park Brake Disk Alignment Tool ..................... Alignment tool centers friction disk assembly and aligns
disk splines for park brake installation.
Park Brake Pack Holding Tool ...................... Tool presses brake plates together to maintain alignment
Service Kits
Park Brake Installation Kit .................................

Tool kit includes park brake alignment tool and
pack holding tool.
Park Brake Disk Alignment Tool ..................... Alignment tool centers friction disk assembly and aligns
disk splines for park brake installation.
Park Brake Pack Holding Tool ...................... Tool presses brake plates together to maintain alignment
299-10-1

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Oreion

Section 30—Engine – Gas Section 299—Service Tools

Section 50—Power Train

Original Instructions. All information, illustrations and specifications in this

Understand Signal Words

Replace Safety Signs

Handle Fluids Safely—Avoid Fires

Prepare for Emergencies

Prevent Battery Explosions

Prevent Acid Burns

Wear Protective Clothing

Avoid High-Pressure Fluids

Avoid Heating Near Pressurized Fluid Lines

Service Machines Safely

Use Proper Tools

Park Machine Safely

Support Machine Properly

Use Proper Lifting Equipment

Work in Clean Area

Protect Against High Pressure Spray

Illuminate Work Area Safely

Work In Ventilated Area

Remove Paint Before Welding or Heating

Avoid Harmful Asbestos Dust

Service Tires Safely

Stay Clear of Rotating Drivelines

Do not install any adapter device that results in a portion of

Service Cooling System Safely

Dispose of Waste Properly

Handle Chemical Products Safely

Live With Safety

Group 10—O-Ring Seal Service Recommendations

Group 15—General Information

4.8 8.8 9.8 10.9 12.9 12.9

4.8 8.8 9.8 10.9 12.9 12.9

Unified Inch Bolt and Screw Torque Values

Face Seal Fittings With Metric Stud Ends Torque

Service Recommendations For Flat Face

Service Recommendations for O-Ring Boss

Continued on next page

NOTE: Torque tolerance is ± 10%.

Size N•m (lb-ft)

CAUTION: Avoid Injury! Gasoline is HIGHLY

To avoid engine damage:

• fill gas tank at the end of each day's operation to help

Break-In Engine Oil - 4-Cycle Gasoline

The following oil is PREFERRED:

The following Oreion Motors oil is also recommended:

• SAE 5W-30 - API Service Classification SE or higher.

Lubricant Storage dust, moisture, and other contamination. Store drums on

Mixing of Lubricants requirements. Mixing different lubricants can interfere with

Chassis Grease • Multi-Purpose HD Lithium Complex Grease

Stroke 66.5 mm (2.618 in.)

Displacement 812 cm3 (49.5 cu-in.)

Spark Plug NGK BKR6 EGP

Continued on next page

Item Measurement Specification

Continued on next page

Item Measurement Specification

Exhaust Pipe to Manifold Nut Torque Torque 73 N·m (54 lb-ft)

Item Measurement Specification

Oil Pan Capacity 2.2 L (2.3 qt.)

Continued on next page

Item Measurement Specification